Author Topic: BMW V8 dry sump from billet  (Read 171992 times)

Offline Stilldrillin

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Re: BMW V8 dry sump from billet
« Reply #325 on: December 10, 2011, 12:29:43 PM »
:bugeye:    Aaawwww......... ADE!!!     :bang:  :bang:

I'm sitting here wi tears in me eyes..... Almost!  :palm:

Oh, man..........  :Doh:

At the very last hurdle. Feel so sorry for you......  :(


Hope the sort out goes ok.

David D
David.

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Still modifying bits of metal... Occasionally, making an improvement!

Offline jim

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Re: BMW V8 dry sump from billet
« Reply #326 on: December 10, 2011, 12:43:42 PM »
Lucky man!!!!

just looking forward to the post about it running!
if i'd thought it through, i'd have never tried it

Offline Dean W

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Re: BMW V8 dry sump from billet
« Reply #327 on: December 10, 2011, 06:06:53 PM »
What a bad break, Ade.  My heart fell when I read the first part!  Thankfully, it sounds
like you have saved the day, again!
Dean W.

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Offline Stilldrillin

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Re: BMW V8 dry sump from billet
« Reply #328 on: December 11, 2011, 02:30:02 AM »
Looking on the bright side.........   :D

Think of all the extra gravel trap clearance!  :lol: :lol:

David D
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Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline Divided he ad

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Re: BMW V8 dry sump from billet
« Reply #329 on: December 12, 2011, 10:19:48 AM »
Ade,

After all this I think you have earned the title of "The luckiest unluckiest Madmodder around"   

In smileys I think this is about right....  :bugeye:  :jaw:  :Doh:  :doh:   :coffee:  :borg:  :dremel:  :headbang:   :beer:


But that's just a guess  :)




Hope it's all going to be alright..... Too much damn hard work not to find a fix  :thumbup:






Ralph.

P.S. A nice coloured anodising is surely the way forward?  :ddb:   
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Offline AdeV

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Re: BMW V8 dry sump from billet
« Reply #330 on: December 12, 2011, 01:45:35 PM »
Thanks again chaps; looks like I managed to fairly accurately convey the depth of feeling - which was proportionate to depth of cut - a proper pucker moment.

Luckily, it's all gone well, and today the very final bits of machining were re-done for the last time (with the engine off the stand & both sump and gearbox mounted up, I used my punch tool to mark the new hole centres. Everything then came apart again, and the four holes were drilled & tapped. No pictures, it's all pretty standard stuff.

Then, the sump was put back on with the brand new gasket, all bolted down, pipes cut & altered to fit. Here are some glamour shots of the engine + sump (sorry for the gross light problems, it was dark in the shed & the sump is shiny shiny...):








Whilst we're here, a crop taken from that last photo shows just how far out I was with my original holes! Since I'm pretty sure I hadn't cut that much metal off in the first place, I must have muffed something when measuring at the gearbox. The small ring just below each the 2 holes, is the threaded bar I loctited in the other day....



For the next sump, I will definitely use the little punch as the FIRST method...

So, finally a couple more:







Should be running by the end of the week, can't wait!  :beer:
Cheers!
Ade.
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Offline Stilldrillin

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Re: BMW V8 dry sump from billet
« Reply #331 on: December 12, 2011, 02:36:25 PM »
A really purposeful looking lump  :clap: :clap: :thumbup:

David D
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline philf

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Re: BMW V8 dry sump from billet
« Reply #332 on: December 12, 2011, 04:32:13 PM »
Ade,

I've followed this thread with great interest since you came to see me in Marple (you bought a right angle bevel gearbox off me) and first told me about MadModder.

I felt sick to the stomach for you when things went awry. As you say, the right hand hole looks to be about 6mm off centre which is perhaps better than being only 1.5mm out - what's left of the plug is more likely to stay put. I am so relieved to see that the loose cutter incident wasn't as catastrophic as it could have been and that you came up with a good fix.
 
You've been an inspiration to us all. I'm sure that not many would attempt a job of that scale. You've obviously had to put great thought into the machining operations and set-ups, learning a lot as you progressed. We've all (or at least, I've) learned whilst watching your progress.

The finished job looks superb. You should be very proud of your achievement and thanks for sharing all the good (and not so good) moments along the way.

Are you having a rest before starting the next?

Cheers. :beer:

Phil.
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Offline dsquire

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Re: BMW V8 dry sump from billet
« Reply #333 on: December 13, 2011, 01:19:51 AM »
Ade

I haven't been saying much but I have been watching this progress since the beginning. It is amazing the way you have turned that big disc of aluminum into what we now see hooked up on the bottom of the engine. I know there were some times along the way that you scared yourself as well as us following along but it appears as though it has all come out with just a few slight design features added. Very well done Ade, you should be proud of this one.  :D :D

Cheers :beer:

Don

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Offline BillTodd

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Re: BMW V8 dry sump from billet
« Reply #334 on: December 13, 2011, 09:16:23 AM »
Fantastic job  :clap:
Bill

Offline winklmj

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Re: BMW V8 dry sump from billet
« Reply #335 on: December 13, 2011, 09:51:47 AM »
Yee Haw (I'm from TX)! I've been watching this since I can't remember--glad you finally got 'er done and it looks great mounted up. Good job.
Mike

Offline rleete

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Re: BMW V8 dry sump from billet
« Reply #336 on: December 13, 2011, 12:28:26 PM »
Anyone have any experience cutting them, as it says can be done?  Why not buy all long units and cut to size?

For less than 100 bucks I could have DRO on my mill.  Far cry from the $600-900 packages available in the past.
Creating scrap, one part at a time

lordedmond

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Re: BMW V8 dry sump from billet
« Reply #337 on: December 13, 2011, 12:53:17 PM »
Ade  how much pongo are you getting at the crank from that M5 lump?



Stuart  ex FF1600 racer

Offline SPiN Racing

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Re: BMW V8 dry sump from billet
« Reply #338 on: December 19, 2011, 09:34:10 AM »
Beautiful job! Looks fantastic!
SPiN Racing

Offline AndreasL

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Re: BMW V8 dry sump from billet
« Reply #339 on: December 21, 2011, 07:11:07 AM »
Stuart  ex FF1600 racer

Aha, one more.  :thumbup:

Offline Divided he ad

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Re: BMW V8 dry sump from billet
« Reply #340 on: December 21, 2011, 12:26:53 PM »
Ade :wave:       Ade....?      Ade  :poke:        Ade!  :wack:         ADE! 







What ya doin?   :scratch:


:coffee:  ? 


 Been awhile and no replies is all  :thumbup:  :)





 Ralph.    :lol:
I know what I know and need to know more!!!

Offline AdeV

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Re: BMW V8 dry sump from billet
« Reply #341 on: December 21, 2011, 02:50:17 PM »
Woah, no need to yell there Ralph....

Currently, there is no further news worthy of reporting... as soon as there is, I'll be posting it here.
Cheers!
Ade.
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Offline Divided he ad

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Re: BMW V8 dry sump from billet
« Reply #342 on: December 21, 2011, 08:16:02 PM »
Only joking chief... I was feeling in a  :poke:  kinda mood  :lol:


Just checkin you were still out there  :thumbup:



Watching this space  :coffee:




Ralph.
I know what I know and need to know more!!!

Offline awemawson

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Re: BMW V8 dry sump from billet
« Reply #343 on: December 29, 2011, 02:57:32 PM »
Ade,

Superb project - I've just read through all 14 pages! No way would I have your patience to do that manually despite having the machinery to do it. I would have spent probably the same time programming it on my CNC, then I could churn them out!

Now you have done it, and before it gets messed up, have it anodised. It will toughen up the surface and keep it good for a long time to come

AWEM
Andrew Mawson
East Sussex

Offline AdeV

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Re: BMW V8 dry sump from billet
« Reply #344 on: January 16, 2012, 03:52:00 PM »
Once again, thanks all for all your kind comments.

AWEM - the sump is already on the car - I hear you about the anodising, but it won't happen just yet. I may be able to do it next winter, but I will have to contract it out, I think the surface area/current requirements will far exceed anything I can muster.

Stuart - currently getting around 450bhp, but we've done all but no tuning work. The main mods are: Remove the VANOS & turn the cams up to 11. Replace BMW ECU with a DTA device. We're running a proprietary ignition/fuel map, the guy who did the work has locked the ECU down, but the kind chaps at DTA have furnished us with the "back door" entry code :med: so we might be tempted to experiment later in the year. Other than that & the dry sump setup, the engine is stock. Next tuning mod is high performance cams (they will allow up to around 600bhp), then it starts getting a bit pricey.

Phil - I'd hoped to be working on another one by now, but illness has prevented that. Once I'm back at the machines, which - work permitting - will be next week, I could get started. Of course, I need a customer first...

And now, for the news:

IT WORKS!!!

The engine has been started & run, and everything is A-OK.... Well, almost; there's a slight leak around the spigots; which is basically due to my faulty spigot design. I should have left room for a washer or, better yet, left a small flange to allow the spigot to seal properly. I'm going to make some new spigots which will be grooved to take an o-ring. I'll also clean up the face on the sump where they tighten up, to ensure a nice oil-tight seal. That should happen next week sometime, depends on when the engine is removed again.

There is still an oil leak into the bellhousing. My money's on a dodgy crank seal, as we know the sump is flat as a flat thing. At least, I know that...

The next photos (other than one of a new spigot) will be of the car on the track hopefully!
Cheers!
Ade.
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lordedmond

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Re: BMW V8 dry sump from billet
« Reply #345 on: January 17, 2012, 03:50:01 AM »
Thanks for the info Ade

not a bad starting Power, :drool:  how much will the block stand before the jelly wobbles set in, I remember talking to Randy Mouse ( oops Andy Rouse ) At Donnington Park long time ago when he was racing ford cosworths ( he was using a Boroscope at the time to check for detonations ) 

He remarked the cossie block seem to turn to jelly at above 700hp  :Doh: that seemed to be the limiting factor

as a side note we got taken round the track in a road  :bug eye: cossie fitted with a hang on tight switch by another ex saloon car champ ( cannot remember his name ) left pits with switch on when the tubo kicked in we was kicked round to 30 degrees to tack wheel spin , the tacho disappeared over the end and never did reappear till we got back to the pits , good ride tho  :D

Stuart now to old to race

Offline HS93

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Re: BMW V8 dry sump from billet
« Reply #346 on: January 17, 2012, 04:13:38 AM »
I am usless at metalwork, Oh and cannot spell either . failure

Offline andyf

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Re: BMW V8 dry sump from billet
« Reply #347 on: January 17, 2012, 05:25:42 AM »
I got one of those O ring sets two years back, Peter. Should last me a lifetime.

 :offtopic: I got one of these from Aldi last year, and they are in again.  http://www.aldi.co.uk/uk/html/offers/special_buys3_22974.htm .
Taps (all second cut) and dies (which aren't split) are M3, 4, 5, 6, 7, 8, 10 and 12, plus 1/8 and 1/4" BSP. Drills are the pilot sizes for the metric taps, and are marked as HSS. I don't know if the taps and dies are HSS, but they certainly seem to cut OK. On the whole, I thought it pretty good value, and the 8x13x1" steel box will come in useful.

Andy
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I've cut the end off it twice, but it's still too short

Offline AdeV

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Re: BMW V8 dry sump from billet
« Reply #348 on: January 17, 2012, 07:27:48 AM »
Stuart - the block is good for over 1000hp (the DTM boys used to run this engine), but that's with regular rebuilds and additional fettling.

It should, however, handle 650 all day long & only require a looking over at the end of the season. It is, essentially, a race engine that lives in a road car.

Peter - I just bought some o-rings off ePay for 6 quid delivered, I reckon they should last me forever, provided I always cut metric holes....

Andy - I tend to pick up most of my taps & dies from a local 2nd hand tool shop. It means I have a vast array of BSW stuff, but there's usually some BSF/UNC/UNF & metric stuff to be had too, it just requires a good rummage around.
Cheers!
Ade.
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lordedmond

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Re: BMW V8 dry sump from billet
« Reply #349 on: January 17, 2012, 08:59:52 AM »
Thanks for the info it looks to be bit stiffer than a 4 pot cossie then  :D


Stuart