hakhawks cosmos e36 coupe

[hakhawk]

so i had all the piping welded this week, and leak tested it today. everything went as expected, no leaks at any of the welds or the intercooler.

only problem was the end cap not staying on the silicon hose at higher pressures, but its not flanged, and the supercharger wont be producing that much boost



so i decided to clean, deburr and paint everything!!

natures spray booth



pipes are all black now, some of them will get stone chipped, but its just paint.



intercooler painted black, only a light coat on the fins/cores, just enough to make them not look silver, using SP139 gm satin black, VHT's recommended paint for radiators



didnt bother painting the back side fins/core, itll never be seen



and yesterday i threw some wrinkle black on the intake pipes and fitted the maf sensor




oh, and the other day i fitted the impeller onto the supercharger. have been putting this off until i knew the compressor housing and everything was 100% as i wanted it so as not to risk damaging it during trial fitting



next weekend is hopefully the test fire/drive around the block. if all goes well, itll get booked in for tuning in the coming weeks.

[Peeunit]

This looks great. You're doing some fantastic work

[hakhawk]

so today i did a lot of small bits and pieces, plumbing in hoses for bypasa valve, map sensor to the ecu, etc. just one less thing to do when its time to bolt it on for good.

i sorted out the hose end for the bypass valve, i'll get this welded this week along with the cooler piping



cut up a couple old belts and bolted them together to work out new belt length. i'll take it to work and find a matching length belt in one piece



bolting it together allowed me to put it on the car and put tension on it. all the pulleys look to line up nicely



also threw on the mechanical tensioner, since the hydraulic ones seem to not like superchargers. from what i could find, this seems to be inside the margins for tensioner. i'll probably grab a couple belts either side of the length just to be sure



sorted out oil drain hose for the charger and put fittings on. gotta love left over braided hose. had to cut one of the old power steering reservoir mounts to clear the silicon hose for the plenum. gave it a buzz down after picture, so no sharp edges



these are the 2 main intercooler pipes that need welding. once welded ill retest, but using the hump hoses gives me a bit of wiggle room anyway



and the intake side of things, bypass valve, catch can fitting, and maf sensor. bottom hose will also get a mounting bracket, so the pod isnt swinging in the breeze.



and car back together with catch can plumbed in. will be interesting to see how much blow by it gets, seeing as i have the group n oil restrictor in place now

[Earl]

I did. I didn't get a reply haha. I figured I can just re-engineer them to work. I actually have a coupe handle coming in the mail so that I can compare it to my handles. I have a compact but we use sedan handles=)

[hakhawk]

still loving them. drivers side is getting a bit dark(lazy driver not washing his hands all the time ) but other than that, theyre awesome. havent failed, trip people out when they try to get out of my car!!

fairly sure the difference with sedan handles is just the screw location/length. tried emailing them about sedan ones?

[Earl]

They look good=) How are you liking the hard motorsport handles now that you have had them for some time? I am trying to figure out what the difference between coupe and sedan handles are to see if I can make them work for me haha

[hakhawk]

cheers, i did. theyre cut down foglight blanks zip tied in place

[Earl]

Coming together great=) Did you make those brake duct delete blanks?

[hakhawk]

so this weekend is test fit/piping mockup/fiddling with all the little things to make it all work before final test run and eventually tuning

installed lines for catch can, removed the old oil/air separator completely. when supercharger goes on, will just need to shorten the outlet hose and add a straight fitting.





mounts came in pretty damn close. i can either add some washers as spacers or just bend the bracket up.



plenty of clearance for the bypass valve(notice i changed the hose fitting to a 90deg, it was bugging me)



time to start messing with intercooler piping

one of the universal pipes to plenum, so close. easy fix



otherwise, fairly easy. second joiner is there because the pipe passing up near the power steering pump will be affixed to the engine.



outlet to cooler is nice and easy.



inlet is simple, 45deg elbow from pod to the 180deg bend i had on the charger via silicon joiner. will make a bracket to bolt this to the chassis. weld in MAF sensor fitting. probably not the ideal lcoation, but theres nowhere else, and i figure where it is on the stock airbox cant be much better



overall shot of the piping



bumper fits



need to make short pipe for the 90deg hose from bypass valve to intake. will probably be fun getting the hose on when its all done. catch can fitting will be about half way down the bend facing backwards.



had to do some clearancing of the sheet metal for the drain fitting. if i have any dramas with this, ill switch back to regular hose and fitting



my ford falcon radiator hose still just hits the pulley. once a belt is added, it will be worse. looks like ill use my short piece of alloy pipe in there afterall



and finally onto the shots everyone actually wants to see








tomorrow ill finish off the bypass valve pipe, double check fitment/position fo the others, make some brackets, then start messing around with working out belt length

[hakhawk]

so catch can stuffs today.

needed a 3/4 to an12 fitting for the rocker cover, couldve bought one, but i had a couple bulkhead fittings from the carbon aribox lying around. bit of time on the lathe and bam, one fitting. (hole in the side is threaded to secure the fitting, so theres no fatigue to the rocker cover piping/hose)



finally decided on a location for the can itself, was hoping to put it on passenger side, but its getting a bit cramped over there, so i relocated the diagnostic plug and used its bracket to bolt the catch can to. hoses will route against scuttle panel and down to rocker cover and intake. access to the drain is nice and easy, no need for an extension hose



oh and yesterday i installed the second fuel pump in the passenger side to stop starvation in corners when the tank gets low. no pics.

[hakhawk]

thanks, forgot to post pics in here, i made a thread the other day with a bunch though

plenum is done. bolted on the bypass valve and air temp sensor to check final fitment. also made an extension for the air temp sensor so i dont need to cut the stock wires(its on bottom of the stock plenum)

heres what it looked like when i got it



and now. certainly not perfect, but a damn sight better i think





walbro fuel pump setup in stock basket, ready to go.

[Falco_e36]

nice color change!

[hakhawk]

finished off today, all works better than it used to, still need to make sure solenoids are working properly, and probably replace them and the pressure valve for the hell of it.

wire brushed and threw some paint on the rocker cover bolts, when i installed it, i wire wheeled them and didnt think about them rusting. oops



while they were drying, i played with the supercharger plenum, marked out and drill/tapped the lower rubber bush holes. need to get a 45deg hose for intercooler piping, the straight aint gonna fit!!



looked at another possible routing for piping, this might give more clearance than between swaybar and rackboot. either way shes gonna be a tight fit



good thing it was tapped a decent amount, finished it off with an adjustable spanner(ps. the pipe thats in the way, lines up nicely where i wanted it to use the original rubber IACV hose, yay!)



the chunks of alloy werent welded in the exact spot i wanted them, so the steel bracket will need some finessing to keep me satisfied, but otherwise, good job me at ligning it all up!!



bolts were dry, time to install new rubber orings, 20 of the bastards!! (yes the vice needs a clean)



and all back together again, started up and ran with no problems, successfull weekend is successful. need to clean the plastic trumpets and rubber intake boots(and most of the engine bay infact, somuchdust)



then i decided to start stripping the plenum of the old paint, since its almost ready for fresh stuff

got about this far before remembering how nasty paint stripper is when it hits you as a fine mist from the wirebrush



long sleeve shirt and some rubber gloves and im back at it



end result





fancy bay shot. looks much nicer than the manky old vanos unit



built by rolls royce...

[hakhawk]

so this weekends mission is to install my rebuilt vanos unit and the group n oil restrictor.

sneaking past the e21 to get to work



didnt take many pics, too busy working

this little nut and bolt was the hardest part of the day, its a 4mm hex on the vanos gear shaft and a 7mm nut. snap the hex off the shaft and its more work involved. correct tools and no problems for me today



old vanos unit succesfully removed, bit grubby under there, cleaned that up best i could before continuing.

fairly sure the vanos wasnt holding timing because pretty much all the seals are shot. the piston literally fell out of its hole after i removed the unit. id say the oil was just gushing past the seal with the high pressures the vanos works at.



light drizzles of rain were persistent today, glad it wasnt overly windy!!



a picture of the elusive oil pump driver, if you drop this while removing the vanos unit, it pretty much drops into the timing cover and cant be removed without pulling a bunch of shit off.



all bolted back on, rocker cover is sitting there for the night, tomorrow ill clean up and paint the bolts, and install new seals



new oil accumulator for the vanos and hardline, had to cut the old line, the flare nut would NOT budge. unsure if the old accumulator was bunk or not, but decided to replace anyway.



no pics of the oil restrictor install, but this is what it looks like. does what it says on the box, restricts the amount of oil getting into the cam tray at high rpm, which generally ends up in the plenum.

to install it requires removing a bung on the side of the head, removing a cam cap and one stud, then inserting it into a hole between the 2 studs.




tomorrow ill clean up and reinstall the rocker cover and coils and such, mark some points on the charger plenum that need ot be drilled and tapped, and do anything else i can think needs test fitting/devising while the plenum is off.

[hakhawk]

more parts arrived for boost prep