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.
23/01/2006
Order and tank
Click me
Click me
Seeing as I have a few days off, I've taken the tank to a metal workshop in Chandlers Ford to add a mini surge tank to the bottom. The tank is not baffled and it £250 to buy the surge tank and twin pump set-up from Marlin. I've decided to modify the main tank and see how it goes first. If I get problems I can always add a surge tank in the front and a second pump at a later date.
09/01/2006
Hi Res!
Click me
08/01/2006
Brakes!
We got the brake pedal back from a friend who was able to bend it for us. Now the positioning is much better giving more room between the accelerator and brakes (we've got big feet!):
Click me
05/01/2006
Sensors
02/01/2006
Intake System Version 2
30/12/2005
Pictures!
29/12/2005
BSP / UNF / NTP errr
28/12/2005
Time to think
On order are silicon hoses, ducts, oil cooler and pipes. After further consideration we're moving the rad further forward, placing the oil cooler in front and getting a "sucker" fan instead. The current position places the rad too close to the engine for me to be comfortable with. We're going to follow Robin's layout for this one, along with his solution for the oil cooler. Thank you for all your help on that one!
Also up for work is the steering column. After enlarging the hole on the bulk head we were able to mount it using the bracket already in the car. However after spending some time sitting in the driver seat we both agreed we didn't like the alignment and have decided to customise it. Using the brake we already made and the now enlarged hole I think we have a steering position that suits our personal taste.
The brake pedal - after several hours of going nowhere trying to bend it, it's time to call in a professional. This stuff is too thick for our weedy gas burner and vice to bend.
Pictures to follow at some point this week.