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.
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.
14/04/2009
Passenger Side
Passenger side speaker
Driver side done
This side still needs some more brackets so it's all solid.
13/04/2009
Fuse box & speakers
Mk 2 fuse holder bracket
This bracket also holds the wiper motor. The clamp has been moved up a bit to reduce flexing.
The centre console is taking shape with a small recess to keep your glasses.
Managed to find some room to fit a speaker above the steering column.
There's some sides and top to try and keep the front and back separated as much as possible.
Once the dash is in you can't see it any more.
11/04/2009
Speakers, hazards and other stuff
Nose cone and centre console
Nose cone fitted.
hmm pretty colours
Starting to piece together the centre console
Two supports cut and shaped to get the angle of the radio correct with enoughclearance for the rear of the radio.
Radio supports glued.
Just need to make up some sides to hold the midbass speakers under the dash.
10/04/2009
Interior and rear lights
Dash board re-trim without glove box (wiper motor in the way)
Rear of re-trimmed dash showing pod for speaker
Divers side behind the dash
Test fit on car, the mount holes needed drilling out as the paint had filled them a bit.
The speakers could do with a grille mesh to finish them off but other than that it is coming together.
Rear lights installed with new waterproof plugs - a bigger job than you might expect!
05/04/2009
Exhaust Hanger Mark 2
Mark 2 exhaust hangers, these use the rubber mounts from a BMW 840Ci Sport. There is 3mm steel plate than connects the exhaust boxes to the hangers.
A new bolt is welded in on the right side of the hanger, the other is the one form the fuel tank strap.
Driver side bracket, this one has some stress on it but the rubber mount is off a 12 year old car so the rubber has gone soft. A new pair will need to be ordered to finalise this.
The plates need a coat of paint and this can be marked as done.
02/04/2009
Clutch Mark 2 Complete
The new clutch system is now installed. The master cylinder has more than enough capacity to dis-engage the clutch without pushing it all the way down. The pedal position can be adjusted with the thread on the master cylinder so we've moved the clutch inline with the brake pedal. Due to the different leverage on the clutch it is now very easy to use. Only time will tell if all the problems are solve once we can go further than the end of the drive!
Constructing the scuttle panel re-enforcement plate
Heating along the cut to bend the 3mm steel.
Re-enforcing the pedal box
The metal is welded on in various places to strengthen the pedal box.
Welding complete on the pedal box
Scuttle re-enforcement plate painted and bolted in place, it bolts on to the bar than runs from one side of the car to the other. There is no flex at all when the clutch is operated now.
Pedal box and new clutch assembly reinstalled in the car.
18/03/2009
Clutch Mark 2
Connected up the clutch this evening, the bite point is right at the bottom of the pedal travel, but is really controllable. It means the clutch will sit higher up that the brake at the moment so we'll have to see how it goes. The whole scuttle bends all over the place so reinforcement is required now.
And finally warm weather - well not freezing anyway :o)
15/03/2009
Clutch Mark 2
Done some work on the new clutch setup:
Bolts through the top of the scuttle to hold the clutch master
Wilwood clutch master mounted to wilwood clutch pedal frame and then bolted to the scuttle.
The scuttle will need some re-enforcement as does the pedal box.
14/03/2009
Body panels
All the body panels are off and ready for paint!
