Welcome to our BMW E30 based Marlin Sportster Build Site,
we hope you will find this documentation interesting and helpful.
The site has grown massively since its inception in 2005, I hope to one day soon improve the navigation as it's a bit overwhelming to start with. The main areas of interest to builders will be:
The rolling chassis build
Bodywork Fitting
SVA Issues
Final Assembly
If you would like read about the build in date order then have a look at his page.
It took 2.5 years to build the car and pass SVA and a lot longer to get to where it is now! To see the Sportster out on the road have a look at one of the videos here.
During 2008 we rebuilt the BMW engine from 2.5 to a 2.8 creating an M20B28 stroker engine. It uses the crankshaft from the later BMW M52B28 and the conrods from the M20B20. Not much more work is needed other than a clean up, slotting those bits together and a crank spacer. To read about the engine build click here (very picture heavy!)
Finally in March 2009 it was painted, a full set of images is here.
To read the whole build from the start click here.
19/07/2010 11:53:06
Complete Kit Car Article
Look out for us in Complete Kit Car this month and next month!
The Latest Issue
The August issue of CKC is crammed with the latest news, features, show previews and your technical issues solved... BUILD • DRIVE • ENJOY
• TIFF. Tiff Needell joins the CKC team as our new monthly contributor.
• MK Indy R. CKC Running Reporter Jack Tait has finished his MK Indy.
• Out & About – California. The Newark Show and Goodwood FoS are on the horizon. Here’s what to expect.
• NG TF – PART TWO. Chris Humphreys’ completed NG TF in all its glory.
• Marlin Sportster Build – Part one. Patrick Short’s build of a BMW based Marlin Sportster.
• Basic Aluminium Fabrication. How to fabricate in aluminium to improve your kit car.
• Road Test – GD427. Is this the best Cobra replica on the planet? Let the numbers decide.
17/04/2010
Engine issues
My M20B28 started making loud high pitch noise. The pitch changed with RPM and seem to reduce under load. I thought it might be a loose belt or a shot bearing. Noise was located near the back of the engine.
After a an hour or so of poking around today it turned out the intake manifold gasket was leaking on cylinder 6.
I'm pretty sure it must have been a materials failure as I've not put that many miles on since the rebuild. Need to order new gaskets, going to do all of them to be sure. Some non-setting gasket sealer has shut it up as a temporary solution :)
09/08/2009
Carbon
Did a little bit of work on the car today, made some carbon fibre scuttle covers. They still need sticking down with the some tape, but they look nice:
07/06/2009
London to Brighton Kit Car Run 2009
It was a bit soggy Sunday morning as it hammered it down on the way to Brooklands. At one point on the M25 I had too look out the side of the car to see where the lanes where! The wipers work fine, on the outside of the car. Masses of spray meant the inside of the screen was wetter than the outside.
On arrival at Brooklands is lighted up and we had a bit of time to dry out before leaving before following the route book to Brighton which was then nice and sunny.
On minor issue with car is that we ended up with a fish bowl in each door - some drain holes required!
Here are some photos:
The Sportster lined up next to two other Marlin's at the Bently Meusum
Parked up in Brighton
Peter arriving a short while after us
A very rare sight to see!
View all the photos from the run, Bently meuseum and at Brighton here
08/05/2009
Stoneleigh 2009 photos
A very nice day out and a good chance to catch up with the other Sportster builders on the MOC (Marlin Owners Club) stand. After a trip round the stands and other cars we came back to find a cup and a trophy on the driver seat "Best Sportster 2009" - well happy with that, thank you to the MOC member who voted :)
02/05/2009
Side screens
Side screen are mounted to aluminium brackets via a threaded hole and cut screw.
Aluminium brackets cut & drilled.
Many, many hours of polishing later brackets ready for mounting.
All done.
26/04/2009
Paint!
It's been a long time coming, but we finally got the Sportster painted and reassembled and here's the result:
25/04/2009
Vents and washer bottle
Demister vent tubing made out of some drain pipe
Scuttle vents, these are from a mini with some stainless mesh added.
Plastic tubed sprayed black and glued to scuttle. Some black rubber acts as a connector to the pipe that came with the heater
a view of the rubber connection on the heater vents
Centre console covered with heater vent built in to direct the warm air at your feet.
Scuttle on with heater pipes attached
Vent pipes attached to scuttle
Bracket to attach screen wash bottle
Screenwash bottle holder
Screen wash tube going through the firewall
Screen wash bottle and motor installed.
12V accessory socket for the GPS
Bodywork coming together
Sorting out the wiring under the scuttle
Sorting out the wiring under the scuttle
Wiper motor and connections.
19/04/2009
Getting there
I was hoping that the car would get finished today, but as always there were more and more little things to do!
The centre console now has bracketing to hold it securely in place, the tub is secured and positioned right for the doors. The doors with re-enforcement brackets are on but not adjusted yet. The demister vent connections are nearly done. I tried setting up the amp with the scope but either them is chucking out some funny signals or the scope is on the blink. Headunit has clean output to setting 60 of 62. Higher than 60 and you get a tiny bit of distortion creep in.
Once the demister vents are sort the scuttle can go on and the doors adjusted. After that it's just bonnet side panels and head lights.
18/04/2009
Centre console, and rear end
The centre console coming together, this will also act as a duct for heater down to your feet. There's also a 12V supply in the side of it for the all important sat nav (or I'd get very lost all the time):
Here is is from a higher vantage point:
The 77MP's styling fits the car quite well:
All the wiring needs a final tidy up after settings are finalised.
Door hinge bracket, one of four. The metal the door is bolted to is far to thin, it flexes all over the place. Hopefully these will add enough structure to fix this.
Exhausts bolted up, bumpers fixed in place, rear lights in place and working. Just needs the other wing and a number plate.