Liam's Z4C race car project

[Mr Tidy]

Good news on the trophy, and even better news about the brakes.

A shame the Birkett won't have any spectators though.

A mate of mine did it years ago with some mates when it was still held at Snetterton and they had a great time - seeing a team of Z4s would have been great!

Anyway I hope it goes well.

 

[Liam22]

Yeah, shame about no spectators, especially as they have been allowed at the last 2 race meetings I've been to.

 

[Mr Tidy]

Yes, I saw the Z4s at Thruxton last month and had been thinking of going to Castle Combe tomorrow - until I looked at the waether forecast!

 

[Liam22]

Quick follow up on the brakes before off-season updates.

The soft pedal immediately came back so I got the system bled with the ABS pump. However, during the process I also reconnected the steering angle sensor, and the pedal became immediately firmer. Right back to normal. So while I'm not 100% sure it seems likely that the DSC unit got confused with the steering angle fault. I know what to do next time.

So, on to the winter upgrades...

Part A is to regain some missing horses. I'll replace or modify the ebay exhaust to improve the breathing. Might try a M54 silencer grafted to the N52 mid section.

Part B is weight saving. Lots of weight saving! I've got a few things planned but also looking for ideas.

The first 2.5kg have come from the front anti roll bar. I previously lamented about the ridiculously heavy E46 M3 27mm ARB is, all 6.7kg of it. Then I discovered that the M3 CSL has a 30.8mm hollow ARB and it was cheaper than buying aftermarket. Strongflex do bushes to fit so an easy fit.




The next 0.5 kg has come from the wiper mechanism. I had already saved 0.5kg by removing the driver side wiper arm so the plan was to remove the redundant bits of linkage. In the end I got carried away and butched it to shorten the passenger lever so that the sweep increased.




The forum watermark has broken my animated GIF but you can see the full extent of the sweep, and the parked position is now almost in the OEM position.

 

[Vanne]

pretty good sweep that Liam, any pics on how you did that? 8)

Heaps of weight can come out of the oem dash. replace it with a race dash.

 

[Liam22]

A race dash isn't going to take the OEM clocks, and then I'm into a world of cost. £100/kg is the target. Polycarbonate windows on order.

For he wiper linkage, I used the driver side lever to make a shorter centre spindle lever. But there's a point at which the lever will foul on the mounting bracket.

 

[Ladderman]

A race dash isn't going to take the OEM clocks, and then I'm into a world of cost. £100/kg is the target. Polycarbonate windows on order.

Hi Liam. Im almost finished converting my garage in to a dedicated Carbon Fibre workshop. I then plan to start making moulds of most of my Z4 interior that I’ve already removed. I do intend on removing the dash & making a Carbon Fibre copy that will take the OEM clocks. If you would be interested please let me know. Obviously at this moment in time I can’t quote the cost, but it’ll be a lot cheaper than mainstream suppliers. You would also have the benefit of personal design input requirements, such as what core materials are used & any FIA regulations that must be met.

I don’t know if you’ve read my post about my project. I’ve already bought all the equipment & materials needed to make resin infusion Carbon Fibre parts. So as mentioned when I finishes the workshop shortly I’ll be ready to start straight away. I will be buying a 3D printer in January that is best suited to make small ABS plastic parts such as clips, lugs & other dash trim holders. This the printer I will be buying https://www.flashforge.com/product-detail/11

At some point next year. I want to make CF exterior body parts, so again if this is of interest to you I’ll be happy to help.

 

[Wursle]

I cant remember where/ if i saw it on this thread but did you run into any issues with removing wiring and it flagging the DTC constantly off? i've removed wiring and now my traction is always off, i need to check to see if its just a fuse but thought id ask on here aswell.

 

[Liam22]

I had the opposite problem where the DSC was constantly on! My preference is for ABS on and DSC off which I achieved by disconnecting the steering angle sensor. However, prolonged disconnection seems to cause a soft brake pedal so it's occasionally reconnected.

FTR, my Sport button and DSC buttons both operate as they did before I started removing things.

 

[Liam22]

I do intend on removing the dash & making a Carbon Fibre copy that will take the OEM clocks. If you would be interested please let me know.

I did see your post (subscribed!). Definitely interested in a CF dash. I will need to check my regs as some championships require the OEM dash to be retained.

When you get to exterior parts I've been looking into side skirts to clean up the airflow under the car. Door cards would also be of interest as mine are heavier than I would like.

 

[Liam22]

Christmas project... Brembo 4-pots from a Megane RS and E46 M3 2-piece discs. Should save 4kg and wear the pads evenly.

 

[Ladderman]

Christmas project... Brembo 4-pots from a Megane RS and E46 M3 2-piece discs. Should save 4kg and wear the pads evenly.

just wondered if you got the Brembo’s fitted ok ?

 

[Liam22]

wondered if you got the Brembo’s fitted ok ?

Err, no. Despite me checking with the seller, the adapter brackets aren't the right size for the M3 discs. I'm now waiting for a revised pair to arrive.

You can see the lack of clearance here

 

[Ladderman]

That’s a shame, it’s turning into a right chew. I hope it doesn’t take long for the new adapter to arrive.

It must be great for those who have the gear to machine there own.

With the advancement in 3D filaments it won’t be long before parts like that could printed.

Hope you get sorted soon

 

[Jakg]

Christmas project... Brembo 4-pots from a Megane RS and E46 M3 2-piece discs. Should save 4kg and wear the pads evenly.

I like!

I had a RenaultSport Megane and it always frustrated me that the Brembo calipers were dirt cheap (I got a set for a MK2 Megane for £120, although I think they are MK3), but all the Brembo adaptors were designed for the Porsche Brembo calipers that were like £500.

 

[Vanne]

sweet selection for claws. have the adapters turned up yet??

 

[Liam22]

The brackets come from Poland and neither the manufacturer or I wanted to risk them getting lost in Brexit customs chaos.

They're now on their way.

I did have a go at making some from 8mm aluminium angle but there's not enough meat for proper threaded holes.

 

[Vanne]

Installed?

 

[Liam22]

Nope.

Currently dealing with a sheared valve cover bolt.

 

[Liam22]

The new brake adapter brackets turned up this week. Positions the caliper 1.5mm further outboard so the M3 discs run smack in the centre.



The total saving over OEM is 6.3kg!!! Unbelievable...

The only snag with the new brackets is that I've now run out of wheel clearance. 3mm spacers now on order.

The brake pad position on the M3 discs is absolutely perfect. No underhang.