MartinClan Sportster Build Construction 2
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Construction 1
Construction 2
Construction 3
Construction 4
Construction 5
Bodywork 1
Bodywork 2
Bodywork 3
Bodywork 4
Bodywork 5
Trim 1
Trim 2
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Donor Vehicle
318is
 
 

 

 

 

 

 

 

New steering column bulkhead fitting
AFM mounting on bracket attached to manifold
Another shot of the AFM. There is still room to fit the diagnostic plug.
AFM from side. The air filter really does miss everything! I used an air filter with a 20 deg offset. Handy when rotating to avoid the bonnet side, alternator and top hose.
       
Final mounting arrangement for AFM with bracket hanging off chassis engine mount
Another picture of the AFM mounting
BMW fuse box and loom embeded in top of passenger bulkhead

mmm..... spaghetti - and yes I do know what the wires all do (well most of them anyway)

Expansion tank. I made the bracket adjustable so that I can level it when the car is complete
Side view with brackets forn AFM, engine relays and expansion tank
Three shots of the engine installation - almost complete!
Test fit of rear body and wheels. Rear body will drop an inch when located properly but it still means the rear of the car needs to drop about another three inches. This should give the exhaust about 4.5 inches clearance - not wonderful but not bad.
Exhaust just poking out from rear of bodywork. Will need to be shortened a few inches.
Rear wheels fill arches OK. The only problem is these are the fronts (7.5J) the rears are 8J - looks like I will have to try and swap them for another couple of 7.5J rims.
Only about 6mm clearance between wheel and bodywork. I think some spacers might be in order...
ECU mounted on side of drivers footwell. Seems to be the best place for it without making major changes to the engine loom.
Wiring from fuse box all terminated in plugs for easy connection. the silver plug is for the dash - so I can wire the dash up on the bench rather than having to lay upside down in the footwell
Engine loom vitually complete. Just need to sort the fuel now and I should be able to run the engine :-)
Another shot of the fusebox embedded in the passenger footwell top
The final cooling system hose cut n shut so that it fits. Took some courage cutting this - a new one from the dealer was £40!
Trial fit of dashboard - OK so its a bit early in the build yet but I needed to see where it went so I could get the heater in the right place. Also showed an unexpected bonus of using the Z3 gearlever - you don't hit your knuckles on the dashboard!
Steering wheel not quite the same angle as the dashboard - I don't think it matters too much.
       

21/05/2006
Mini heater installed on top of transmission tunnel. OK so the domestic plumbing bits look a bit naff but it's simple, cheap and when painted black you won't even see them.

19/06/2006
I bonded the floor in place first using sikaflex and self tappers through the holes drilled for the rivets into some timber to clamp it in place. I didn't fancy trying to set the 40 rivets in the short time it takes for the sika to start setting. I covered the timber in sellotape first to make sure it didn't get stuck.

This was a messy job as I used far to much sikaflex and it oozed out everywhere. I think I will use some masking tape when I do the other side - and less sikaflex.

20/06/2006
Once the sika had gone off I removed the timber and started setting the rivets. I got about halfway through before deciding my old spiralux rivet tool wasn't really up to the job - I am going to have to get something a bit more heavy duty to finish it off.

02/07/2006
While I have been waiting for my new pop rivet tool to arrive so I can complete the floors I have been doing a redesign of the fuel system. I am going for the minimum number of joins and so I think I might use flexi's to go from front to back rather than the copper. I have still to measure all the pipes lengths. It's suprising how many pipes and clips I am going to need to do a 'proper job'