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Unread 05-04-2009, 12:41 PM
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Default McCall's Z3 M Roadtser LS1 Project

Jason is very busy so I figured I'd start a build thread for his car and let him do the updates from here on out. We got a lot done on Saturday morning so the project is in full swing!


As purchased the car had some great parts (and some messes to fix) but no motor

This car was a former autocross/drag car with a turbo BMW 6. It was for sale with all sorts of go fast goodies but no motor, and Jason grabbed it up for a V8 swap. Giant CCW 3-piece wheels (18x10.5" front, 18x11" rear) and a lot of rear frame reinforcement for an E36 style "dual ear mount" diff, with a Rogue finned diff cover. A built diff with a Quaife LSD.

Jason, Paul M and I went to Florida and back on a 36 hour non-stop round trip to get the car in Feb 2008. Since then the car has been essentially stripped down to the tub, being readied for the LS1 install, and now the drivetrain is going in.

Suspension needs major help (the old shocks are all blown and/or locked up, so they need to be rebuilt and replaced with ASTs). The brakes are a mess - some Wilwood lightweight stuff, but its all jacked up with some home-brew hard lines, a line lock, and more - that all needs to go. Jason has already relocated the ABS pump (its in the way of the LS1) and moved it under the dash, like in our Alpha car, and ditched the line lock. We're going to try to get him into a full RacingBrake Big Brake Kit (we'll be selling their wares soon) and then he can re-plumb all of the brakes correctly.




The interior has been pulled out and the sheet metal repainted. 2-tone steering wheel is FOR SALE.

The fuel tank is full of old fuel (which is now varnish) so it needs to be cleaned out thoroughly, a higher flow fuel pump installed (WalBro 255 lph should do it) and then all new fuel lines run.


LS1 Camaro engine going in

Jason found a complete, running Camaro LS1/T-56 last year - which was curiously enough installed in a 1996 Mustang Cobra - and he bought it for a good price. The transmission went through a quick rebuild and then he added a LS7 clutch and lightweight aluminum flywheel. He went a little crazy and bought an electric water pump and Katech idler (the anodized blue bits on front - its looks pretty baller). A new TurnOne "race" power steering pump (like the one we're using) is going on soon, as well as a new alternator, and then its ready to crank.


Yours truly, lining up the motor mounts

Last weekend I went over and helped him install the drivetrain using the Vorshlag/DP motor mounts and transmission crossmember kits. These went in with little effort (we had to dimple the trans tunnel slightly in 2 small places, no biggie - these parts were made for an E36 chassis after all) and everything line up perfectly. On Sunday I brought our Alpha car's headers by for a test fit and they went in perfectly as well.


L: VoMo/DP Trans crossmember fit great. R: So do the full length headers

So all he needs next is a custom driveshaft (VERY short), and the normal wiring and plumbing to get the car on the road. We're going to be pushing him to finish it this summer, so he doesn't missing another season of track and autocross events. The final weight should be under 2300 pounds (yikes!) so this will be a thrill ride, even with stock (340 whp) power levels. After its had some shake down runs it will get a full cage and some other upgrades, as needed.


Ready to be re-assembled and DRIVEN!

Last edited by Fair!; 05-04-2009 at 02:23 PM.
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Unread 05-04-2009, 02:49 PM
Thinkkker Thinkkker is offline
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Default Re: McCall's Z3 M Roadtser LS1 Project

From the way it sounds this is going to be a race car. Is this correct?
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Unread 06-01-2009, 11:18 AM
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Default Re: McCall's Z3 M Roadtser LS1 Project

Quote:
Originally Posted by Thinkkker View Post
From the way it sounds this is going to be a race car. Is this correct?
Uhh, yea. It quit being a street car before he bought it. Although, you never know with McCall. I think he's going to reinstall the dash and maybe the center console (that's all it needs to meet the "modified" class for Redline Time Attack!).

Here's a brief summary on this car/project that McCall posted on 5/4/2009 over on Bimmerforums, after I started his project thread there:

Quote:
Originally Posted by McCall
Thanks for prodding me enough and finally starting a build thread for me Fair. I just didn't want to start a thread too early as I knew work would be limited quite a bit this last year and didn't want to have one of those project started threads that never gets finished and the poster just disappears. My job also has me traveling a bunch so there may be some time between posts. My schedule is getting a bit lighter plus parts are starting to come together so things should continue to move along in the next few months so now it makes sense to start posting up about the project.

The car - '00 M Roadster, 24k original miles. Now before you BMW purists start, this car has lead a very rough life and was a partially disassembled rolling chassis plus cut up a bit before I got a hold of it. Basically it was no spring chicken! The car came with full complement of chassis upgrades (coil-overs, dual-tab diff mount), the afore mentioned CCWs, TC Kline carbon fiber hood, Fluiddyne radiator, and matching hardtop (no I'm not selling it)

Plans - Dual purpose SCCA X-Prepared autoxer plus a NASA TTU Time Trialer. The car will still be "streetable" but overall it will be a pretty much gutted out dedicated race car. I will retain the dash and some semblance of interior pieces though.

Project Timeline - The goal right now is to have the car running around the autox course by August. Will it be completely finished by then? Heck no but at least it will be moving quickly under its own power and I can start to work out the bugs. After it runs a few local events, I'll start on the full cage and a bunch of other upgrades that will allow the car to compete in time trials.

First off, big thanks to the Vorshlag boys for helping to brainstorming this project idea and then getting/building the right parts for the job. *Big disclaimer* - both Fair and Hanchey are long time friends of mine going back 20 years so this thread, of course, will be biased toward their kit.

As Fair stated, this past weekend saw some great strides as we confirmed that not only the E36 motor mounts worked in the Roadster, but both the tranny crossmember and the headers fit as well with no modifications! So anyone wanting to do a Z3 roadster (or Coupe- please someone do a Coupe!), the Vorshlag LS1 E36 kit is a "bolt-in". The only part I will not be able to use from their off-the-shelf kit is the driveshaft, but I'm going to use their same Vendor. The length is going to be the only the difference. I'll post up pics and dimensions here once that part is ordered/delivered. Vomo will probably take that info and be able to offer it in a Z3 kit Iím sure.

I'll continue to use this tread to post updates and pictures as the car starts to come together. After I get the headers, steering, and front end back on the car, the next step is to work on the all new fuel system (maybe a fuel cell??), then I'll re-do all the brake lines, cooling system, then I'll finally tackle the complete wiring harness.
http://www.youtube.com/watch?v=ZLhKZ53h5jg

The previous owner of this car also posted this video, from when they had the car running an S52 with a huge turbo (11.1@130 mph drag race pass.

Last edited by Fair!; 01-10-2011 at 03:51 PM.
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Unread 02-01-2010, 09:49 PM
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Default Re: McCall's Z3 M Roadtser LS1 Project

Update for Jan 26, 2010: Long time no update! After buying, modding and racing the old Vorshlag E30 318is several months ago, McCall has actually been working on this Z3 LS1 project and fits and spurts, with the majority of the progress happening late in 2009. Some old friends flew into town and they spent much of a weekend installing some rear suspension bits. The car now has the rear diff and suspension back in the car, after some much needed fab cleanup and new offset camber adjustment bolts (from Ireland, who source them from an E39 BMW 5-series).


Fuel system upgrades underway

He and friend Ed tackled some early fuel system upgrades, adding billet fuel rails, a Fuel Pressure Regulator, and started running -4 braided feed and return lines from the stock tank to.... somewhere. (ignore the caption above that says -8 lines). A gaggle of fittings and line sizes are needed to finish this out. After a brief sidetrack with a potential custom fuel cell (crazy!), and a slight intervention for sanity, the fuel system plan now looks more thought out. An existing Wlabro 255 lph in-tank pump will round out the fuel system, as well as (I hope?) some upgraded injectors and an LS6 intake.


FAST fuel rails and Aeromotive FP regulator shown installed

I stopped by on the 26th and brought a "standard E36 length" T56/LS1 swap driveshaft we had built for a customer that week, mocking it up onto the transmission and measuring for fit into the Z3 chassis. The Z3 driveshaft is nearly 10" shorter, but as you can see the shifter location is moved several inches forward of the stock location (which "feels" fine when sitting in the car, actually). The steering shaft also needs to be substantially longer, but all our other Vorshlag E36 LS1 swap parts work in the Z3 without modification, including the headers, motor mounts and trans crossmember.


Right: I need to make a longer 2-piece steering shaft to attach to the U-joints he purchased from us

I'm building the driveshaft this week and will take pics of it in the car soon. Also have to make a longer steering shaft. The driveshaft and the final work on the fuel system are the last things needed before tackling the wiring and other plumbing issues (fuel, coolant, brakes). Then... its time to put the wheels back on, fill up the fluids, and crank it.

Lots to do...

Last edited by Fair!; 01-10-2011 at 06:24 PM.
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Unread 05-28-2010, 07:20 PM
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Default Re: McCall's Z3 M Roadtser LS1 Project

Update for May 28th, 2010: Trying to keep Jason motivated on this project is becoming difficult!

This weekend I'm going to try to get the new Z3 steering shaft built and installed on this car, so it is at least easier to push around. The custom Z3 length driveshaft is already on the car, but damn if I can find any pictures I took...

More soon!
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Unread 06-21-2010, 05:04 PM
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Default Re: McCall's Z3 M Roadtser LS1 Project

Update!!! Yes, it's on like Donkey Kong now and I WANT to get this car running before the end of the summer!

Fair delivered my beautiful new steering shaft & p1mp driveshaft. The driveshaft is in and I just got new bolts/nuts to mount it to the MZ3 diff so check that off the list. The steering shaft will be in (maybe tonight) so the car is officially a full rolling car again.

My credit card is still smoking as I just ordered the following-
LS6 intake/tb/fuel injectors
Techrod custom wiring harness
new plugs/wires
3 last adapters/fitting for the AN fuel system
Hawk HP+ pads F&R
Turn-One Power Steering Pump
Set-back shift lever (I hope it works)
gas pedal

Parts that have arrived and need to be installed-
E36 M3 front calipers/brackets (going to be selling off the non-vented Willwood set-up)
Two-piece M3 rotors
Sparco seats/slider
AN -8 fuel lines, fuel filter, fittings, adapters
FAST Fuel rail

Still to be done-
Mount ABS module (custom bracket needed)
New front hard brake lines L&R
Flare/fittings for both rear brake lines
New SS flex brake lines for the the front
Mount Radiator (custom brackets needed)
Determine radiator hoses/overflow solution
full custom exhaust
Find used headlights
install dash/center console
wiring, wiring, wiring

So, in the coming weeks I'll be working on this inbetween travel and the $2010 project car. I might also try to plan a few works nights to get some help knocking this stuff out. Pizza/beer will be offered up!
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Unread 06-21-2010, 05:38 PM
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Default Re: McCall's Z3 M Roadtser LS1 Project

You have 30 days till the UTCC. Put in an entry and make it happen. Folks work best under a deadline.




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Unread 06-21-2010, 06:05 PM
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Default Re: McCall's Z3 M Roadtser LS1 Project

So what has a better chance? McCall's roadster or the dirty thirty? Pick one and go people!!
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Unread 06-21-2010, 06:09 PM
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Default Re: McCall's Z3 M Roadtser LS1 Project

Quote:
Originally Posted by hancheyb View Post
So what has a better chance? McCall's roadster or the dirty thirty? Pick one and go people!!
Haha, oh it will be the E30 as we've gotten too far to turn back now!!
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Unread 06-21-2010, 07:10 PM
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Default Re: McCall's Z3 M Roadtser LS1 Project

Mini update for June 21, 2010: Some pictures of Z3 parts we built for Jason's M Roadster...





McCall has a bunch of new accessories to install next.

Last edited by Fair!; 01-10-2011 at 04:42 PM.
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