Liam's Z4C race car project

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MrPT
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Liam's Z4C race car project

Post by MrPT » Fri Mar 15, 2019 3:21 pm

That is interesting that you bought the bush press kit and also have a hydraulic press. I recently invested in one of those kits after realising that I didn't have the space/cash for a decent press. Good to know that they're up to the job! I haven't had any issues so far either, although eccentric bushes presented a bit of a challenge (solved just by using the thinnest threaded rod at a slight angle).

Another forum member, bradz, had his rear subframe sent off for shot/peen blasting and a powder coat. It feels like a good idea for a component that takes as much abuse as it does.
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Liam's Z4C race car project

Post by Liam22 » Fri Mar 15, 2019 5:39 pm

The hydraulic press is good for small, flat items with plenty of "meat" around the edges. The front lollipops work well in it, but the trailing arms and subframe are too big to fit squarely in the press.

No time to send things away for blasting. POR15 will seal the rust and provide a hard wearing surface. It won't be super-smooth but it'll be pretty good. I want to have the subframe and trailing arms painted and ready to go back on the car by the end of the weekend :D

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Liam's Z4C race car project

Post by Liam22 » Sun Mar 17, 2019 10:46 pm

That was a productive weekend!

Masked up the bores of the bushes so that the paint wouldn't reduce their size.
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While the first coat was drying I set about the trailing arms with flap wheel and wire brush.
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Managed to get 2 coats on during Saturday and left them to harden overnight.
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Sunday afternoon started with the painstaking job of removing all the masking tape and cleaning up all the mating faces. Then the fun job of fitting the new bushes. A bar clamp was very useful for this.
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The rear upright also needed new inboard joints for the wishbones. New balljoints top and bottom.
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And finally, after a little head-scratching about the orientation of the front subframe bushes, I'm ready to start getting all this back on the car.
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Liam's Z4C race car project

Post by R60BBA » Sun Mar 17, 2019 10:49 pm

Nice thread and car OP.

Good to see things done properly. :thumbsup:
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Liam's Z4C race car project

Post by Liam22 » Mon Mar 18, 2019 11:04 am

First time I've used Strongflex bushes and quite pleased so far. Thought this was a nice touch:
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Liam's Z4C race car project

Post by Liam22 » Tue Mar 26, 2019 10:15 am

Progress has been slow this last week. Today was my original target for a shakedown trackday, but I've not yet even started re-assembling the suspension.

It doesn't help that I decided to overhaul the gear shift/selector bushes while access is improved without a propshaft installed. One of the retaining pins for the shift arm front bushes is seized in the gearbox casing so I'm gonna have to remove the transmission mounts/bracket to get bigger tools in there. Why didn't I wait until I was changing the clutch... :headbang:

The only tangible progress has been to replace the diff oil. Mine doesn't have a drain plug so with the diff currently out of the subframe I just tipped it upside down and drained it that way. Just under a litre came out so I put 1 litre back in.

My spirits were lifted yesterday when I came home from work to find a box of shiny bits from GAZ. These are Gaz Monotubes (not the usual Golds). Dampers and top mounts from the E46 330 Cup race series, spring rates from the ZCars series. I expect I'll fine tune the spring rates once I get down to race weight and add some aero.
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Liam's Z4C race car project

Post by Liam22 » Wed Mar 27, 2019 11:00 am

Liam22 wrote:
Tue Mar 26, 2019 10:15 am
It doesn't help that I decided to overhaul the gear shift/selector bushes while access is improved without a propshaft installed. One of the retaining pins for the shift arm front bushes is seized in the gearbox casing so I'm gonna have to remove the transmission mounts/bracket to get bigger tools in there. Why didn't I wait until I was changing the clutch...
Sod it! I'm going to drop the 'box and change the flywheel/clutch while I have the propshaft off. Ordered the TTV Racing single-mass lightweight flywheel, and Sachs Performance clutch kit :evil:

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Liam's Z4C race car project

Post by MACK » Wed Mar 27, 2019 1:04 pm

Liam22 wrote:
Tue Mar 12, 2019 10:58 am
Kaaz DBW3020 should drop straight in with the 3.46 FD. That seems reasonably short and should see 145mph at the redline in 5th. Are shorter FDs available?
If your talking standard open diffs there's a 3.64 available on post face lift 3.0 autos and pre face lift 2.5 autos. there's even a 3.73 fitted to post face lift 2.5si autos if you can find any of these. Aftermarket wise I'm not sure about others but I know Quaiffe do a slip diff in these sizes.
I've got a 3.64 fitted to my pre 3.0i (open diff still no LSD just yet) in my road going zed. But I am running the M tyre sizes so it actually equates to the 3.46 with standard tyres. Going from a standard 3.07 which effectively became a 2.93 with these tyres, to effectively a 3.46 made a huge difference to the car, really livened it up and as this is the diff ratio a standard coupe runs not the extreme at all. I think the move from 3.07 in pre 3.0i to the 3.23 in the 3.0si vert and the 3.46si in the coupe (all using the same box/ratio) go along way to explaining why folks often say the later cars have a lot more urgency about them. That and an extra 30bhp of course! :D
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Liam's Z4C race car project

Post by Liam22 » Mon Apr 15, 2019 11:09 pm

Flywheel and clutch kit have arrived and I finally had a chance to drop the gearbox today.

Spent way too much time trying to remove the gear lever. The plastic cup just didn't want to come away from the carrier. But thankfully that was the hardest part. Worked my way around the bell housing, removing the E-bolts, all of which came away with ease thanks to the being aluminium.
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The gearbox glided away from the engine on a transmission cradle atop a trolley jack. This has come in useful many times now.
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With the gearbox on the floor I could finally tap out the pin that was stuck in the gear shift carrier. What a faff!
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The clutch is in great condition. Looks almost new, but it's clear that the gearbox has never been removed before. Impressive.
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Unfortunately my T60 torx socket sheared apart after the second flywheel bolt, so I had to pack up for the day without removing the flywheel. Gonna need a 1/2" drive impact version, and a flywheel locking tool before I can finish the job.

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Liam's Z4C race car project

Post by stupot1 » Tue Apr 16, 2019 8:16 am

Great write up and interesting to follow
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