Vorshlag $2010 GRM Challenge car - BMW E30 V8

[Fair!]

Re: Vorshlag $2010 GRM Challenge car - BMW E30 V8

Update for June 14, 2010 - PART I: We got a lot done this past weekend - I put in a good 18-20 hours over those 2 days, Chris worked all day Sunday and Paul M worked both days on the lathe. Thanks, guys! Anyway, here's the stuff we worked on.

Paul spent his two days on our little manual lathe cutting up a chunk of cylindrical Nylon into some custom rear subframe bushings. To save money we made these from scratch instead of buying any of the common poly or aluminum replacement bushings - any of which are a MASSIVE improvement over the stock rubber bushings, which allow TONS of subframe/diff movement. Any sane person would simply BUY some aftermarket pieces, but due to this INsane budget of $2010 we had to make them.



We sketched up the stock stuff, then I jotted down my 2-piece Nylon idea, and we cut out the OEM bushing cores from the stock rear subframe housing with a SawsAll. Paul then took these rubber covered, square shaped aluminum internal pieces and whittled them into a usable, cylindrical shape we could slide them into in the finished nylon bushings. The old rubber made a huge, sticky mess!





Then he cut the round cylinder of Nylon into 4 usable chunks, using a parting tool and some cutting fluid. Nylon is a chore to machine - gets gummy messy fast.



The trick is to get the cutting speeds/depths just right so you have a steady stream of nylon coming off....



You have to stop the machine often when the continuous strand of Nylon gets wrapped around the part (it always does!). A test of patience on a manual lathe like this.



Paul did an awesome job (and was a machinist in a former job many eons ago) - I could never have made these in the time frame he did, nor with this level of quality control. He had all measurements within .001" and everything slid perfectly into place!



The lower pieces were tricky in that they had to have a recessed pocket to clear the lower stock locating bracket/washer.



With those finished late Saturday we bolted the subframe housing into place. This was a major hurdle and lets us finally install the modded trailing arms, finish mounting the diff (have to set the pinion angle and drill two holes), and get to work on the rear brakes. It more importantly lets us put some springs in the back and set the car on the rear wheels!

More updates from last weekend below...

[Fair!]

Re: Vorshlag $2010 GRM Challenge car - BMW E30 V8

Update for June 14, 2010 - PART II: While Paul worked the lathe on Saturday I finish welded the rear diff mount structure we added, organized all of our parts into labeled boxes, installed some other misc. parts we had, and got the car level/square on the lift to start mock-up for the new trans crossmember.



I weighed the used aluminum race seat we just bought for a great price. I took it inside and came back 5 minutes later - the shop cat Luke had already curled up into and taken a nap in the new seat. Great... its now covered in fur, of course.



On Sunday I worked on a new trans crossmember with Chris. We had changed from one T5 to another, as well as to a .... weird configuration with respect to the bellhousing. When doing this it rotated the trans 15 degrees, but this lined up the shifter better with the tunnel and floor. So I had to make an all new trans crossmember. That means starting over from scratch with respect to measuring drive line angles, then re-doing all of that fab work.





Many hours later we had the new unit bolted back into the car (we'll paint it later this week). This new configuration adds more room for exhaust routing on the driver's side, under the trans, which is a nice bonus. The passenger side inner part of the floor pan sits higher than the driver's side, so it can route well on that side anyway. This is assuming we run dual 3" exhausts to at least the middle of the car, which is the plan.



Then I took the tacked-together motor mounts and finish welded all of the pieces, then Chris primed and painted those. There are 2 more main motor side pieces I'm not showing - I have seen how smart some forum readers are, and they'd figure out the motor in seconds if I showed these. All the pieces are back in the car now and all of that is wrapped up.



Lastly, while Chris and I waited on Paul to finish the subframe bushings, we took some measurements and pics of the two tires we have lined up for use on this car. The 18x11" CCW wheels are mounted up with some old 305/30/18 Hoosiers (this is similar to the tires we'll use for the GRM UTCC event in July), and the 15x10" steel wheels have some very used 275/35/15 Hoosiers (this is the package we'll use for the GRM Challenge events in October).





Surprisingly the 275 on the 15x10" wheel has only about 1/2" less tread (10.5") than the 305 on the 18x11" (11" of tread), but the 15" tire is almost 3" shorter. That will affect gearing a bit - need to go run the numbers!

More work this week (Tues and Thurs) including driveshaft measure/shorten/cut/weld, rear brake mock-up, rear fender cutting for tire clearance, and (my least favorite!).... header fab begins.

More soon,

[Fair!]

Re: Vorshlag $2010 GRM Challenge car - BMW E30 V8

Update for June 16, 2010: We had 4 people here Tuesday night and we worked for about 4 hours. Got a lot done... all of the suspension is bolted on the car now, all 4 wheels are on, and we started playing with ride heights. Oh, and we caught the car on fire about 12 times.


Rear diff mount structure seam sealed, taped, primed and painted - then the E30 diff with the E36 cover was installed


Trailing arms and new rotors installed. Then several rear wheels and tires were test fit


Rear fenders were roughed in with the plasma cutter. Mayhem ensued


Ride height testing took a while. We got it to 5" clearance under the steering rack and 6" under the fuel tank. These M3 fenders won't be cut up!


Its ghetto looking but it looks mean on 18x11s with 305 Hoosiers

We also mocked-up/measured our driveshaft set-up, worked on the a rear diff/speed sensor interference solution, and installed the front rotors as well. Lots more to do, but at least it rolls, steers, and almost stops. Thanks to Chris, Sean, and Brian for helping last night! We're at it again this Thursday and I'm digging into the car (header fab?) all weekend.

Cheers,

[Hunter]

Re: Vorshlag $2010 GRM Challenge car - BMW E30 V8

wow yall are doing some really nice work on this one

[Fair!]

Re: Vorshlag $2010 GRM Challenge car - BMW E30 V8

Update for June 18th, 2010: It was a busy night with a record 10 different GRM Team members showing up at one point or another, with another 3-4 that couldn't make it. The GRM Project Team has really grown and I honestly lost count! Thanks to everyone who came by last night to work. I didn't do much on the car myself until the wee hours of the morning, long after everyone had left, as I was performing some drywall/insulation repairs all night in preparation for some work a plumber is here wrapping up this morning.

A bit of what was done last night can't be shown yet. Motor stuff. The power steering pump is on so now almost all the accessories are in place, which will let me get the radiator mocked-up and I can work on brackets and the main coolant lines this weekend. I did get the radiator in place at about 3 am and found some used radiator hoses that I can cut-up and splice together to use on this motor. Some are from this very car and others are from a box of used BMW hoses I keep for "emergency spares". Both of my E46s got a full "preemptive coolant system replacement", so their old hoses will make good donors.


A well used, stock E36 radiator (used for years in the Alpha car) sits in place with a good 1/2" to the front of the motor (ha!)

We used some more old radiator hoses for the fuel filler neck relocation, as well as an old BMW swaybar bracket. This car is getting all sorts of recycled parts! The original filler neck location (at the passenger side rear fender) is getting covered up by flares soon and the filler neck/vent tubes were in the way of the 18x11" wheels, on the inside rim area. Now the filler neck will be at the back of the trunk for somewhat easy fill-ups. More importantly I won't spend 6+ hours relocating the stock filler door assembly in the left rear wheel flare, and doing more bodywork (shudder) to make it look pretty. I think I found the swaybar bracket, but Derek and Chris tackled the heavy lifting on this one and it came out great.


Fuel filler neck and cap relocation worked great and cost $0

More inboard rear wheel room was found by chopping off part of the rear upper spring perch, which is over-sized for the 60mm coilover springs we'll be using. Chris manned the plasma cutter and Derek welded up the new edge to gain us about 3/4" inboard on both sides.




Left: more room gained here out back for the 18x11" wheels. Right: Up front there's plenty of room to the E36 strut/spring

Our newest team member Brian kept busy all night and got the HVAC box buttoned up put the dash back in. This was a job nobody wanted to touch, and he did it with a smile. Other than one trim ring around the gauge cluster (which I had never seen in place - it came with the car in the trunk) and the center console (awaiting my tunnel patch repair) the dash bits are done.





Costas built some E36 steering rack bushings to get the height of the rack set relative to the E30 K-member, so its finally wrapped up. He also got the custom 2-piece steering shaft (which may or may not make it in the final $2010 budget) installed, Loctited, and marked with paint to show its done.



Sean pulled the trans crossmember off, cleaned it up and painted it, then I bolted it back on this morning. We also got the V6 Camaro steel driveshaft (came with the trans) in place and marked for a simple cut/weld, which we'll do over the weekend.



Question: Can someone who knows more about E30 fuel systems than any of us tell me what each of these fuel lines is at the tank?


Left: What is all of this crap? Right: New rotors installed last Tuesday night

Chris got the inspection cover off from the rear seat area and we all got a little bleary-eyed trying to figure out the fuel system and vent routing. So... many... lines... There are 3 lines going to the old filler neck (a vent, spillover tube, and ???) and some more coming out of this cover that we cannot identify. It looks like there's a pump inside the tank and an external as well - is this a crossover pump? We might have to drop the tank (which isn't a bad idea - the old fuel needs to be cleaned out and a big dent pushed out) to figure all of this out over the weekend. We got a used, stock Subaru 200 lph electric pump for $0 (it was being thrown out/replaced) that should feed our little motor, which I had planned on putting inside the tank in place of the stocker.

A 4 liter SPA fire system is headed our way from Elephant Motorsports (thanks Jack!), so that will go in next week, along with the aluminum seat and a custom slider (which I dread making). Over this coming weekend I want to get the coolant lines to the heater core, a remote reservoir (that I need to scrounge to find), and the radiator completed; radiator brackets built; power steering hoses made/started; master cylinder mounted/plumbed; the LR fender plasma cut for the big wheels; the driveshaft wrapped up; original front fenders installed and cut for tire clearance; and get a start on the headers. I might be getting some bodywork help for Saturday, as David is flying in from Boston for the weekend and wants to lend a hand. Paul M is coming by to machine that speed sensor spacer for the diff cover, and I think McCall is stopping by Saturday as well.

If anyone in the DFW area that is good with bodywork and/or paint wants to join the team, we need you!

Check in on Monday for more updates,

[Fair!]

Re: Vorshlag $2010 GRM Challenge car - BMW E30 V8

Update for June 22, 2010: Busy Monday - sorry this update is a day late. I worked part of Saturday and all day Sunday in the shop with a bit of help both days. I spent Saturday morning working on Paul M's Subaru project then spent the afternoon attacking our E30 project. Saturday afternoon Chris, McCall, and his cousin David (our very remote paint & bodywork consultant) were here and we hacked away at some bodywork related bits. On Sunday Brian joined me for various other fab chores.


Chris got the Right Front and Left Rear fenders plasma cut for the big tires

Paul M came by and machined us a nylon spacer for the speed sensor, to allow the E36 diff cover to clear the reluctor ring in the E30 diff. With a little cutting on the backside of the cover and some longer bolts it should work nicely. Chris got to plasma cutting and some other jobs while David got to making us a mock-up flare. He was going to do some bodywork but every section that needed his attention was too FUBAR to complete in one day. So I was his assistant while he worked his flare design magic in cardboard... he was itching to move straight to metal, but we ran out of time.





The mock-up is sort of crude but he gave me a lot of good ideas and tips on how to make these from 20 gauge sheet with minimal welding/warpage. If we get time before UTCC I will attack these, otherwise it will happen in August/September, before paint and before the October GRM Challenge.

McCall spent the afternoon cutting out a piece of sheet metal to cover the mangled mess that was the transmission tunnel. The previous owners hacked out a huge hole just forward of the shifter hole (to do some repair?) that they then slapped some fiberglass over. The new T5 shifter poked up right between these two holes, so he cut the whole area out and made this patch with the proper shifter hole and locating stud for the console in it.



On Sunday I did the final fit-up for the shifter and welded it in place, then covered the seam in some leftover seam sealer from the E46 roof swap. Then I primed and painted it all, mocked up the shifter and rowed through the gears.





I finished that up on Sunday, then Brian and I made a front driveshaft loop:



Then Brian cut the old mounts off the condenser and we started mounting the E30's electric aux (a/c) fan in front of the radiator.



Last but not least we made some lightweight upper radiator brackets out of some scraps of scraps of 20 gauge sheet. Some old heater hose was cut up and used for rubber grommets in the top of the used E36 radiator and these brackets clip into those and bolt to the old forward flipping hood hinge mounts (we're going to pin the hood on to save weight). I dinged the radiator support on one side slightly to get the radiator as far forward as possible. the lower part of the radiator just sits on top of the stock E30 rubber mounts - this was an easy radiator swap, actually. I found the old E30 remote coolant reservoir so we'll make a mount for it and re-use it. Recycle, reuse!



So I've moved the work schedule (at least mine!) up to 6 days a week to try to meet our deadlines... 4 nights and both weekend days. Still looking for a used E36 high pressure power steering hose (just need the rack banjo end) and we still desperately need a paint and body volunteer.

The GRM crew is already arriving so I'm going out to the shop to work some more!

[John in Houston]

Re: Vorshlag $2010 GRM Challenge car - BMW E30 V8

You just need the banjo fitting? I think I have my 'broken' line from the last time it blew off. Let me check tonight. If I have it, you got it.

If not, I Know I have the cooler loop as it cracked me in the head last weekend. Is that fitting the same size?

[Fair!]

Re: Vorshlag $2010 GRM Challenge car - BMW E30 V8

You just need the banjo fitting? I think I have my 'broken' line from the last time it blew off. Let me check tonight. If I have it, you got it.

If not, I Know I have the cooler loop as it cracked me in the head last weekend. Is that fitting the same size?

Thanks! The high pressure side is the smaller M14 thru bolt. The cooler loop is the low pressure side - larger, with the M16 bolt.

[Fair!]

Re: Vorshlag $2010 GRM Challenge car - BMW E30 V8

Update for June 23, 2010: We had a large crew on hand last night, and got some more done on the E30. We don't have many pictures this morning but I'll show what I've got. I worked most of the evening on the headers and I got the upper part of all four primaries on one side done. Can't show that yet.



Paul C and Chris and some others worked on pulling the fuel tank. It had a lot of fuel in it - who knows how old that crud is? Old fuel tends to turn to varnish and plug up everything. They drained it (into a container for me to take and have disposed of properly today), removed in-tank transfer pump and fuel level sender, and yanked the plethora of vent lines. We're going to wash it out a bit, once its free of fuel fumes we're going to bang out the massive dent on the bottom of one side of the saddle tank. Then put it back in later this week and start to route our fuel lines. Normally we'd slap new -8 braided fuel lines and AN fittings on everything and be done with it. But for a $2010 car we're re-using the stock feed and return hard lines - they should just barely be big enough for our modest power goals for this engine - to save on material costs.



He also cleaned up the ragged edges on the front fender left behind by the plasma cutter. He used the air nibbler, which is a noisy little air tool that makes beautifully clean cuts in thin sheet metal.



Paul M clearanced the E36 diff cover for the E30 reluctor ring, and now it all clears with the speed sensor moved back .300" with the nylon spacer he made last weekend.



McCall pulled the E36 front calipers and disassembled them for a quick seal rebuild. He got the bodies cleaned inside and out with a brass wire wheel. The pistons looked good but the seals were definitely trashed - not exactly shocking from calipers that we rescued that someone was throwing away.



The old E30's a/c electric fan got mounted to the radiator surround by Paul C and Chris with a little help from me late in the evening. We re-used the old rubber mounts at all 3 points and made some simple brackets to bolt it all to the car. The finished result is rigid, has room for a power steering cooler (if we add one) behind it, and uses the factory wiring.


That's all of last nights work I can show... more work tonight, Thursday night and Saturday.

Cheers,

[John in Houston]

Re: Vorshlag $2010 GRM Challenge car - BMW E30 V8

The cooler loop is the low pressure side - larger, with the M16 bolt.

Only have the low pressure side... sorry

[Fair!]

Re: Vorshlag $2010 GRM Challenge car - BMW E30 V8

Only have the low pressure side... sorry

No worries... we found a fitting

[Fair!]

Re: Vorshlag $2010 GRM Challenge car - BMW E30 V8

Update for June 24, 2010: I didn't get to work on the E30 or E46 last night, but worked on Paul M's Subaru instead (we got the transmission in!).

Today we had to put another car where the E30 was, so we realized its finally together enough to bolt wheels on, steer and roll around. We pushed it outside for a second and I snapped some pics, showing the current state of the car now. I've hidden the engine (which is in and being wired up/headers built) but nothing else.







More project car work tonight - people are already starting to arrive. Lots to do!

[Fair!]

Re: Vorshlag $2010 GRM Challenge car - BMW E30 V8

Update for June 25, 2010: We had a crew of 5 last night and we got a bit more work knocked out.

I was looking at the back fender areas we had clearanced for the big tires, and it was a jagged mess after the plasma cutter did its thing through both layers of sheet metal. I was trying to tie the inner fender structure back to the outer fender contour, to give it strength, to keep water/fumes out of the passenger area, and to give us a sturdy structure to build the flares off of at a later date.



I started by grinding off the plasma'd edge, which was pretty nasty and had globs of molten steel that had fused into little "steelcicles". Once that was cleaned up it was time to join the two edges - the inner and outer fenders. This is usually a royal pain on an E36, as there's 3 layers and they are usually pretty far apart after you cut upwards for bigger tires, but on the E30 they weren't that far apart when cut up ~3" or so. The cut fenders started out flapping and flimsy, but by inching along with careful tack welds, hammering the inner structure into shape between tacks, I found that I could join the two structures pretty easily.



I had a little trouble on the left rear, as the guy who plasma'd that one cut too much off the inside and I had a 1" gap between the sheets for about 7" of length. I took a piece of scrap 20 gauge, cut it with the hand sheers, and tacked it to the inner structure. Then I hammered it over the edge at the same ~90° angle that the rest of the curved edge had formed, and then welded it to the outer sheet metal. Its all going to be covered up eventually. After about 2 hours both fenders were fully joined along the entire arch lengths and were mostly water tight. We'll go over the joined seams with "kitty hair putty" (fiberglass infused resin) or the seam sealer, at least.



The old E30 coolant reservoir was found in one of the big boxes of "old stuff we removed", and we found a new place to hide it - behind the passenger side strut tower. Its out of the way here but still located up high for better filling/bleeding. We even found the old coolant level sensor, which capped off the top. We made some brackets out of a few inches of bent 1/8" steel strap welded to the strut tower, drilled a couple of holes, then seam sealed and painted them. The reservoir bolts in place with the hardware from Tractor Supply Co's "buy it by the pound" super cheap 3/8" inch sized bolts and nuts. You can buy Grade 8 SAE bits there for dirt cheap - and no, they don't sell metric anything. Again, we'd normally try to keep a German car 100% metric, but at this budget we can't be that picky!



After cleaning up the jagged cut edge in the trunk floor opening, Brian P spent the evening inside the cabin installing more interior bits, like the gauge surround and the center console. Looks like we need to trim the console opening a tick to clear the shifter (doh!) but we'll try to make it look as stock as possible. The carpet will go in after UTCC, but before the GRM Challenge. No need to add fuel for the fire for the VIR event.



Next up was a caliper rebuild for the front, and our new stock brake hoses arrived Thursday as well. Oh, we could have bought new non-M E36 calipers @ $0 to the budget ("OEM brakes/parts are free"), but we got these for dirt cheap and the seal rebuild kits were like $5/each. We figured - why not paint them red? That's worth at least +15 hp. I had a can of some ancient "high heat red" engine paint, probably from the 1990s, and Sean gave the calipers a few coats of red just for fun. The paint will likely vaporize during the first lap on track, but what the hell.



Fitting the E36 non-M rear brakes are more of a challenge than the front, as we're stuck with old E30 trailing arms which were made for different caliper bolt spacings and rotor diameters. Chris spent some time and carefully cut off the old cast steel caliper mounts from the trailing arms, cooling the metal to avoid damaging the bearings or paint on the unit. He cut them off and ground the pad flat, and now we'll build some new caliper brackets. A steel shop in town gave me a 6" x 6" piece of 1/2" plate that was in there "drops pile", and we'll cut out a new bracket and weld the sucker on at the correct offset for these brakes and the unusual E36 non-M hub locations (which are 3/4" more inboard than the E30 hubs).



Matt cleaned up the greasy E30 LSD diff we purchased for this build ($100!) and shot it with some black spray paint. Its the real diff getting the E36 rear cover soon and going in the car. Hope it works. Thanks to everyone that came Thursday night - come by Saturday if you've got any time.

[Fair!]

Re: Vorshlag $2010 GRM Challenge car - BMW E30 V8

Update for June 28, 2010: Paul Magyar and Paul Costas both came by Saturday morning to work on the E30 project while I was making seat brackets for my E46 330 DSP car (I had a race the next day, of course!). They got a lot done in about 4 hours of work, then Costas stuck around another couple of hours to help me design and build the slider seat bracket for my 330 (and I worked till midnight to get them both built and harnesses in the car - and raced Sunday in 102° heat - but it was fun!). Here's where we are:



Magyar machined the little plug above that we needed for an extra oil dipstick tube we aren't using. He took a chunk of scrap round bar (that was an old tool rest for a band saw I threw out last year) and whittled out this little piece. Even added an O-ring groove and a chamfer. Pretty slick! Above he's shown shortening a piece of old fuel filler neck tubing for use on custom radiator hoses (see below).



Then they got the E36 diff cover onto the E30 LSD 2.79 rear diff that we're using in the car, made an RTV gasket, and got it bolted in the car. Then they put the driveshaft we cut/welded in the car, then the E30 half shafts and got the back of the car mostly buttoned up. I picked up the AST4100 rears from AST today, that we're using just for the UTCC event (the used Bilsteins will be on the car for the $2010 GRM Challenge) and we'll install the shocks tonight.



You can also see the custom radiator hose they built, made from two old/used radiator hoses. They spliced the various bends together using a piece of tubing that was once part of this E30's fuel filler neck (more recycled parts - I never throw anything away if I can help it!) and it worked great. Costas showed us a neat trick he learned from ThinkFast author & IndyCar engineer Neil Roberts - how to safety wire a worm gear hose clamp so it never gets loose:



That trick was so slick I had to share it. You can buy Neil's excellent book here at Vorshlag.

I bought a little piece of aluminum bar at a machine supply place today for a few bucks that Magyar will machine into various fittings and adapters for the heater hose and coolant reservoir piping (that I'd normally buy - but its all about saving budget money at this point). This car will have a functional heater/defrost, of course.

A bunch of parts are going on the car tonight, so I should have another, "more meaty" update tomorrow. The 3 day weekend coming up? Its full court press time!!

[Fair!]

Re: Vorshlag $2010 GRM Challenge car - BMW E30 V8

Update for June 30, 2010: We had a nice sized crew last night and worked on several things. We worked on a number of things that I cannot show yet, including the hybrid power steering hose and the upper radiator hose, both of which are done and on the car. The throttle cable is as well. Here's the stuff we can show...


First off was the fuel tank - it went back in after it was removed/cleaned/painted last weekend, and some short sections of new fuel hose were added, a few things were capped off, and others were re-routed. Nice to have the tank buttoned up and checked off the list. Then Sean and Chris installed the red painted (bling!) E36 non-M calipers and checked that off the build list, and there's a gratuitous trans crossmember picture as well (painted), from underneath the car.



Chris and Sean removed the E30 tie rods I had installed a few weeks ago - as they were much too long. The car had 2" of toe out and we ran out of adjustment. So if you've got an E36 spindle, E36 struts, and E36 steering rack - stick with the E36 tie rods. We reinstalled the old ones that came on this E36 rack, and now the toe can adjust back into a usable zone. Sorry guys... I made some extra work for yall.



Brian Hanchey of AST-USA stopped by after hours to pick up some parts and got a laugh watching 5 people try to do the work of two. Eventually I found something for some idle hands to do on the front of the car, so McCall and I could mock-up the E36 caliper brackets, calipers, pads and rotors on the E30 trailing arm.



Since this is a Frankenstein rear brake creation, we knew we had to make new caliper brackets and weld them to the trailing arm. Since we went to E36 non-M rear rotors (to match the E36 non-M front rotors/calipers and master cylinder we're using), the Z3 rear calipers need to be spaced away from the trailing arm father to compensate for the slightly larger (1/2"?) rear rotor diameter. And since we have a goofy conglomeration of E36 non-M hubs, E36 rotors, and E30 trailing arms, the caliper offset is all wrong. We mocked everything up, added compressed air (see left picture, above) to the brake line, and that squeezed the caliper tight to the rotor at the correct placement. We added .050" thick shims to space the caliper bracket away from the edge of the rotor and measured the gap between the old mounting bracket and where it needed to weld to.



We painted some layup fluid onto the small piece of 1/2" plate scrap I scored last week, traced the old caliper mount brackets Chris cut off the E30 trailing arms, added the distance we needed for proper rotor spacing, then McCall started drilling the 10mm holes. Next, we'd cut it out on the band saw and tack weld it on.... but...

I broke the blade on my crappy band saw last Saturday (forcing me to use a cut off wheel on a die grinder to complete my E46 seat brackets - and pissing me off royally), so I picked up a new blade yesterday. Installed it last night while McCall was drilling, and something looked... wrong. Dammit, the teeth are pointing the wrong way! It cannot cut with the blade oriented backwards, and you can't flip it without cutting and re-welding the blade - gotta get a new one today. So we had no band saw to cut the caliper pattern out, and that ended the night at 11:30 PM. Oh well, I got an excuse to finally watch last week's European Grand Prix. What a race!

Magyar and I are working on the car tonight, wrapping up the cooling system hoses/adapters and other plumbing issues, and I'll finally mount the power steering cooler.