After a few years of Auto-x and DE's I decided to take the next step and turn my e30 into a full blown race car. Like many builds posted here, this is a "rolling project" so progress is made in chunks.

I purchased the car from a buddy where it had been relegated to nothing more than a parts car. The shell and a pile of parts for $600 was the perfect candidate to test and tune the m20 turbo motor I had built for another project. Soon that "other project" was on the back burner and the e30 was getting the star treatment while I became addicted to auto-xing it. After a year or so I realized my turbo setup was not the most competitive package for auto-x. It was a very potent track (DE) package but a few nagging problems kept it from being as competitive as I wanted for Auto-X.

In an effort to be more competitive I sourced a used S50 and a few boxes of bolt-ons - the official point of no return had been reached. The car was finally competitive and more importantly it was reliable. After another year of auto-x and DE's I finally decided it was time to step up to the next level and start racing fender-to-fender.

The car in it's final "street" appearance:
http://img.photobucket.com/albums/v521/iflytii/bmw-okspeed%20autox/earlymorning2.jpg

Getting started on the cage:
http://img.photobucket.com/albums/v521/iflytii/roll%20cage/bender-4.jpg
http://img.photobucket.com/albums/v521/iflytii/roll%20cage/mainhoop.jpg

Rear plinth blocks:
http://img.photobucket.com/albums/v521/iflytii/roll%20cage/blocks.jpg

Fitting before welding:
http://img.photobucket.com/albums/v521/iflytii/roll%20cage/cage_04-29-07_fitted_3.jpg
http://img.photobucket.com/albums/v521/iflytii/roll%20cage/cage_04-29-07_fitted_4.jpg

First big mistake - I fit the main hoop snug to the bottom of the sunroof cassette. Then it dawned on me to cut the sunroof cassette out - leaving a gaping 1.5" that would have allowed me to raise the main hoop. After a quick seat mock-up we determined there was plenty of head room so we pressed on.
http://img.photobucket.com/albums/v521/iflytii/roll%20cage/progress_4050507.jpg

Final welding:
http://img.photobucket.com/albums/v521/iflytii/roll%20cage/progress_1050607.jpg
http://img.photobucket.com/albums/v521/iflytii/roll%20cage/progress_2050607.jpg
http://img.photobucket.com/albums/v521/iflytii/roll%20cage/progress_3050607.jpg
Dropping the cage to get the top welded:
http://img.photobucket.com/albums/v521/iflytii/roll%20cage/progress_5050607.jpg

Got the basic cage finished up and the car back together (with MUCH help from some good friends) and with a successful tech I made it out to my first "real" race. :redspot

As if I wasn't nervous enough my first time out, it rained all weekend and I only brought slicks. :shifty
http://img.photobucket.com/albums/v521/iflytii/hallett/hallett%20052707/D-030.jpg

http://img.photobucket.com/albums/v521/iflytii/hallett/hallet%20062407/J-083.jpg
http://img.photobucket.com/albums/v521/iflytii/e30-misc/100_2351_cropped.jpg

...After a few races with my local series (COMMA), my flywheel decided to "fall off" so the car was put up for the rest of the season to finish it up and re-build the motor.

More additions to the cage:
http://img.photobucket.com/albums/v521/iflytii/roll%20cage/strutbracing.jpg
http://img.photobucket.com/albums/v521/iflytii/roll%20cage/diagbracing.jpg

Started playing with ideas for the A-pillar:
http://img.photobucket.com/albums/v521/iflytii/roll%20cage/a-pillar.jpg

Planning on reinforcing the A-pillar and gusseting the door bars, then I think I can finally paint the interior!

nice welding!

nice welding!

Thanks but I can not take credit for any of the Tig welding. A buddy of mine helped me build the cage and he did all the tig welding. I can mig pretty good but I felt much more confident recruiting the help of an expert for the important stuff.

Some more build photos in random order (most of these were done before the cage):

Rear trailing arm reinforcements
http://img.photobucket.com/albums/v521/iflytii/325%20suspension/e30_trailing-arm-4.jpg

Rear suspension
http://img.photobucket.com/albums/v521/iflytii/325%20suspension/suspension-3.jpg

Brakes:
Front Massive brakes
http://img.photobucket.com/albums/v521/iflytii/325%20suspension/DSC00767.jpg

Rear brakes- not much out there for 318 ti trailing arms so I took a rotor, had it turned down and drilled to accept an aftermarket Wilwood rotor. With some much appreciated consultation with Lee (Massive Brakes) I think I ended up with a decent solution.
http://img.photobucket.com/albums/v521/iflytii/big%20brakes/tibbkcompare.jpg
http://img.photobucket.com/albums/v521/iflytii/big%20brakes/reartimockup.jpg

I've been anxious to see the finished product. Can't wait!

I've been anxious to see the finished product. Can't wait!

I'll add you to the list, right behind me and Jules... :D

Speaking of finished product, I did some doodling in photoshop to try and finalize my paint scheme (finally time for the primer fenders to go!)

My first quick sketch (DM to throw off my competition):
http://img.photobucket.com/albums/v521/iflytii/e30%20paint/e30racecarschemeA.jpg

A refined version that a friend did for me that I think turned out great. He used a M3 as his canvas but I think the idea show well regardless.
http://img.photobucket.com/albums/v521/iflytii/e30%20paint/sample1.jpg

Paint looks sick!

Love the little cars... :D

All looks real good here. Simple clean cage with some sweet welds. Very ice car.:buttrock

Love the little cars... :D

All looks real good here. Simple clean cage with some sweet welds. Very ice car.:buttrock

Thanks! :D

Made some progress this past week. Fresh paint! At least part of the car looks decent now.

http://img.photobucket.com/albums/v521/iflytii/e30-steering/DSC00797.jpg

Hopefully weather will cooperate this weekend and I can get the motor in the car!

http://img.photobucket.com/albums/v521/iflytii/s50/s50_HCbuild1.jpg
http://img.photobucket.com/albums/v521/iflytii/s50/s50head2.jpg
http://img.photobucket.com/albums/v521/iflytii/s50/s50_HCbuild2.jpg

What did you use for the clutch/brake setup, swap out the pedals to manual? What did you use for the steering rack column, that doesn't look stock.

What did you use for the clutch/brake setup, swap out the pedals to manual? What did you use for the steering rack column, that doesn't look stock.

I'm using a Tilton pedal assembly and a Woodward collapsible steering column. The steering shaft is a combination of parts - the lower U-joint from a Vorshlag kit (www.vorshlag.com) and the upper U-Joint is from Woodward to match the spline on their steering column. A standard DD shaft connects them.

You can see the pedals and steering shaft in this interior pic:
http://img.photobucket.com/albums/v521/iflytii/e30-wiring/DSC00798.jpg

This build looks awesome!
I'm actually in the middle of installing the Tilton Pedals that you have... in my e30 M3 build.
Do you happen to have any pictures of the interior side of the pedal install, just for my curiosity... Looks like what I'm doing...
Great build!

amazing work man, and an amazing car

This build looks awesome!
I'm actually in the middle of installing the Tilton Pedals that you have... in my e30 M3 build.
Do you happen to have any pictures of the interior side of the pedal install, just for my curiosity... Looks like what I'm doing...
Great build!

I'll take some better pics of the pedal install tonight. FYI, in case you didn't know, VAC Motorsports sells a firewall reinforcement plate specifically for these pedals.

I have a crappy monitor, but are the pistons coated? if so what did you go with?

Where did you get the fiberglass dash? Looks like an amazing build so far, cant wait to see more!

I have a crappy monitor, but are the pistons coated? if so what did you go with?

Yes, the pistons are coated. I used www.swaintech.com and couldn't be happier with their service. I did their TBC coating (Ceramic Thermal Barrier) on the domes and PC-9 coating on skirts.

Where did you get the fiberglass dash? Looks like an amazing build so far, cant wait to see more!

Thanks! Picked up the dash from a guy on R3vlimited, Ary (widebodye30). His company is http://www.eurostopusa.com/.

I'll take some better pics of the pedal install tonight. FYI, in case you didn't know, VAC Motorsports sells a firewall reinforcement plate specifically for these pedals.

Thanks! I'm just curious to see how you did it... I'm really looking forward to seeing the pics. Also, which master cylinder is that you're using for the clutch?

And, it's funny you mention that plate that VAC sells... I have that plate, since it was so inexpensive that it wasn't worth fabbing one up myself.
Thanks again!

Good choice on the coatings, too;)... I'm looking forward to having mine back from Swaintech soon.

Very nice work. Can't wait to see the car fully painted.

Thanks! :D

Made some progress this past week. Fresh paint! At least part of the car looks decent now.

http://img.photobucket.com/albums/v521/iflytii/e30-steering/DSC00797.jpg

Hopefully weather will cooperate this weekend and I can get the motor in the car!

http://img.photobucket.com/albums/v521/iflytii/s50/s50_HCbuild1.jpg

That looks like a million bucks :buttrock

Wow, looks great!
I am in the process of building my own E30 race car and this thread is very interesting. Good work! Keep us up to date, please.

Thanks! I'm just curious to see how you did it... I'm really looking forward to seeing the pics. Also, which master cylinder is that you're using for the clutch?

And, it's funny you mention that plate that VAC sells... I have that plate, since it was so inexpensive that it wasn't worth fabbing one up myself.
Thanks again!

Good choice on the coatings, too;)... I'm looking forward to having mine back from Swaintech soon.

Going to start with a 7/10" master cylinder for the clutch. I am using a Tilton hydraulic TOB so my application might be different than yours.
http://img.photobucket.com/albums/v521/iflytii/e30-driveline/DSC00795.jpg

Here are a couple pic of the pedals installed. Sorry, not the best pics.
http://img.photobucket.com/albums/v521/iflytii/e30-steering/DSC00803.jpg
http://img.photobucket.com/albums/v521/iflytii/e30-steering/DSC00802.jpg

I had a friend rework the throttle linkage since the new pedals interfered with it's location.
http://img.photobucket.com/albums/v521/iflytii/e30-steering/DSC00804.jpg

Messed around with making a center net mount on the dash tonight. Going to drop it down nearly flush with the dash before it gets fully welded to the dash bar.

http://img.photobucket.com/albums/v521/iflytii/e30-wiring/DSC00805.jpg

FYI Tilton specs a 5/8" clutch MC to be used with their release bearing.

Also, is that a VAc release bearing adapter? When did he start making them?

FYI Tilton specs a 5/8" clutch MC to be used with their release bearing.

Also, is that a VAc release bearing adapter? When did he start making them?

I threw a 7/10" on because I shortened the master cylinder shaft length to get the pedals adjusted more to my liking (they stuck out too far even fully adjusted). Perhaps my logic was flawed thinking with a shorter stroke a larger diameter would make up the difference? I've got a 5/8" now just in case that doesn't work out when I attempt to set the clutch stop.

Yes, that is a VAC adapter. Not sure when they started making them but I purchased it back in September 2007.

Going to start with a 7/10" master cylinder for the clutch. I am using a Tilton hydraulic TOB so my application might be different than yours.
http://img.photobucket.com/albums/v521/iflytii/e30-driveline/DSC00795.jpg

Here are a couple pic of the pedals installed. Sorry, not the best pics.
http://img.photobucket.com/albums/v521/iflytii/e30-steering/DSC00803.jpg
http://img.photobucket.com/albums/v521/iflytii/e30-steering/DSC00802.jpg

I had a friend rework the throttle linkage since the new pedals interfered with it's location.
http://img.photobucket.com/albums/v521/iflytii/e30-steering/DSC00804.jpg

Those pics look great, too.. Very nice install of the pedals... Very similar to my choice.
I was/am going to weld the plate on the interior side of the firewall, so as not to have the pedals too far forward.. I "mapped it out" as far as location of the originals vs. the new cluster. Maybe I'll reconsider, as it would be easier to do the welding on the engine side like you did.

You're right about the clutch master... I'm using the stock clutch configuration for now, so I'll be using a different clutch master than you are.
Nice clutch setup, too.:)
Thanks for the pics!!

Got the motor in, finally! The removable core support proved to be worth the efffort!

http://img.photobucket.com/albums/v521/iflytii/e30-misc/IMG_3421.jpg
http://img.photobucket.com/albums/v521/iflytii/e30-misc/IMG_3424.jpg
http://img.photobucket.com/albums/v521/iflytii/e30-misc/IMG_3426.jpg

great news. that garage looks a little cleaner than the last time i saw it ;)

This is a really nice build.

I like your attention to detail.

Please keep us updated as things progress.

Paul Q

What does this removable core support look like removed and how are you attaching it?

What does this removable core support look like removed and how are you attaching it?

I'll get some core support pics this weekend. Here is the lower attachment point (the core is now boxed).

http://img.photobucket.com/albums/v521/iflytii/roll%20cage/details/removeit1.jpg

Weekend update :

Got the trunk pinned and my new wing mocked up. Looks like I will need minimal bracing for the wing mount since the placement of the pins worked out so well.

http://img.photobucket.com/albums/v521/iflytii/e30%20paint/DSC00811.jpg

Got some gusseting done (Thanks Craig for dragging the tig back over!).

My dog inspecting the work:
http://img.photobucket.com/albums/v521/iflytii/roll%20cage/DSC00807.jpg

Planning on one more gusset, under the X and then I think the cage is finally ready for paint.
http://img.photobucket.com/albums/v521/iflytii/roll%20cage/DSC00809.jpg

Seems like your removable core is a hot topic :)

What does this removable core support look like removed and how are you attaching it?


Here are a couple quick pics from this morning. Note that I'm not finished but this should give you a good idea of how it works.

Upper connection - I boxed the end then used a piece of angle to create the bracket. If you look at any of the previous engine bay pics, you will see the corresponding mounting holes.
http://img.photobucket.com/albums/v521/iflytii/roll%20cage/details/core-1.jpg

The lower connection was reinforced (boxed) with some 1" square tube. The same angle was used here too creating the connection point.
http://img.photobucket.com/albums/v521/iflytii/roll%20cage/details/core-2.jpg

this is great inspiration! My wife say's I can do this if I do it this cleanly.

She doesn't want to step over alot of crap just to get to the trashcans..question,did you do all the cutting and welding in your garage,and if so what kinda complaints did you get from your neighbors?

The reason I ask ,I have done cutting and welding and it is not the most spectator friendly things to do...any way's keep up the good work

Chris

this is great inspiration! My wife say's I can do this if I do it this cleanly.

She doesn't want to step over alot of crap just to get to the trashcans..question,did you do all the cutting and welding in your garage,and if so what kinda complaints did you get from your neighbors?

The reason I ask ,I have done cutting and welding and it is not the most spectator friendly things to do...any way's keep up the good work

Chris

I won't post a picture of my living room, your wife will nix your project aspirations on the spot! :D

Almost all the work has been done right in my little garage - I try and keep all the noisy projects inside the garage and shut down at a reasonable time in the evenings. My city has an ordinance that prohibits any kind of automobile work outside your garage. With a project of this scope and a small 1 car garage I have occasionally done some work outside but, I really try to keep it to a minimum. If the car goes out for any extended period of time the car cover goes on it. I've not had any problems with the city or with any of my neighbors. Of course being limited by space and schedule I have probably doubled the time it would take to complete this project in a proper facility.

I won't post a picture of my living room, your wife will nix your project aspirations on the spot!

Almost all the work has been done right in my little garage - I try and keep all the noisy projects inside the garage and shut down at a reasonable time in the evenings. My city has an ordinance that prohibits any kind of automobile work outside your garage. With a project of this scope and a small 1 car garage I have occasionally done some work outside but, I really try to keep it to a minimum. If the car goes out for any extended period of time the car cover goes on it. I've not had any problems with the city or with any of my neighbors. Of course being limited by space and schedule I have probably doubled the time it would take to complete this project in a proper facility.


Tell me about it, the only difference is that we have 10 feet of snow here...

Wow, awesome build Bob.

Nice work! Glad to see the pedals put to good use.

let's see an update :D

Here ya go Joseph... :D

Progress has been slow the past couple months. Took the car to the body shop over a month ago expecting to have the rear quarters, doors and fenders ready for paint as well a the interior painted a couple weeks ago. The quarters ended up being problematic for a couple reasons and the interior paint didn't turn out as well as I would have liked so it's been a frustrating few weeks. Anyway, here are a few progress pixs as of a three weeks ago:

http://img.photobucket.com/albums/v521/iflytii/roll%20cage/IMG_3709.jpg
http://img.photobucket.com/albums/v521/iflytii/roll%20cage/IMG_3708.jpg
http://img.photobucket.com/albums/v521/iflytii/roll%20cage/IMG_3707.jpg

Unfortunately the rear quarters that I had hoped would clear some big rubber actually gave me less clearance than anticipated. I ended up having to combine an additional flare to the box flares to clear 280's. The additional flares will changed a bit and bonded to the box flare rather than bolted.

http://img.photobucket.com/albums/v521/iflytii/e30%20paint/IMG_3705.jpg

Another shot from the side.

http://img.photobucket.com/albums/v521/iflytii/e30%20paint/IMG_3713.jpg

I'll have to get some more updated pixs from the last few weeks.

What rear flares did you originally use? FiberArtz?

I think Mike Akard has some super mondo flares?!?!?

Also, what front fenders are you running? What size tire are you trying to run in the front?

Thanks for the pics!

What rear flares did you originally use? FiberArtz?

I think Mike Akard has some super mondo flares?!?!?

Also, what front fenders are you running? What size tire are you trying to run in the front?

Thanks for the pics!

The fenders and rear flares (minus the 240 additions) are from eurostopusa.com. The fronts are DTM copies, the same as Mike's I think. If I can't make something decent out of my fiberglass collection I'll have to see if he has any extra flares... :D

I was thinking a 250/640 on an 18x10" up front. Actually I was thinking that would be a good size all around but I wanted the option to run a larger staggered size in back in the future.

The fenders and rear flares (minus the 240 additions) are from eurostopusa.com. The fronts are DTM copies, the same as Mike's I think. If I can't make something decent out of my fiberglass collection I'll have to see if he has any extra flares... :D

I was thinking a 250/640 on an 18x10" up front. Actually I was thinking that would be a good size all around but I wanted the option to run a larger staggered size in back in the future.

Cool - with the weight you can probably get the car down to, I bet the 250 slick in a super soft compound would be almost perfect all the way around! They will heat up nicely.

You could easily run them on 18x9 wheels also.

I run 280/650/18 on 18x10 on my E46 all the way around and we have trouble getting heat into the tires on all but the hottest summer weekends.

Looks great!!

Looks very nice

amazing!!! keep that way