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.
25/09/2007
SVA Date!
SVA man from Southampton called today - we've got a date! Next Friday 5th
Also booked an MOT for Tuesday afternoon to check emissions and have a pro look over the car!
Insurance is also sorted thanks to Adrian Flux
23/09/2007
The small things
Some more small things today:
- Indicators bolted down, they need moving back bit to avoid hitting the front wings on full lock
- Interior some more zip ties on the wiring
- Oil topped up
- Test the brakes on the drive way - seems easy enough to lock the wheels at low speed
- Steering wheel sponge cover tweaked a bit
- All lights checked
- Heater cover added and 90 rubber bends to point the air flow at our feet
- Cleaned the garage up, it was starting to look a bit messy!
22/09/2007
Indicators, horns, wiring and interior lighting
More small jobs sorted today while waiting for an SVA date:
Indicators installed so that they comply with SVA regs:
Installed new horns as the ones from the donor died:
Finally clean up of the engine wiring loom:
Interior lighting, these run on a dely circuit so when you open the door they stay on for a period of time. They also turn on when you unlock the car with the alarm for a longer period or until the engine is started.:
16/09/2007
Steering Wheel
A bit of a dilema! The steering wheel. The E30 wheel would pass SVA just fine, however the steering column is at a very shallow angle therefore it probably wont pass. The solution a collapsable boss. No problem the momo wheel has that, but its got a few sharp edges on it. So the solution, hopefully, is this:
You can still use the horn button through the sponge but there a nice head impact friendly centre piece!
15/09/2007
Small update
Been trying to bleed the coolant in the engine but nothing has been coming out the hole! So took the thermostat housing cover off. There was a big build up of deposits in there. The engine block itself the other side of the thermostat looked fine. So I'm guessing running mostly on idle with the stat closed has caused it. Anyway the stat is fine, tested it in boiling water.
Cleaned up the housing cover, ran some coolant flush through the system for 10mins, drained it then filled up with 25% antifreeze 75% distilled water.
Also set the speedo, big thanks to Stuart for the guide
14/09/2007
SVA
Small SVA related update. Got a letter from VOSA asking for proof that I built the car so I've photocopied lots of invoices and printed some pictures from the site to send to them!
11/09/2007
SVA
The SVA1 form went in the post today! Just need to make sure the car is ready for the SVA now! :D
09/09/2007
Interior work, max and some nearly ready pictures!
The sets of pics today:
Interior:
Gear gaitor now completed properly. Handbrake gaiter, this has the original E30 rubber cover (top part of rubber only) underneath so there''s nothing sharp to cause an issue at SVA.
The boot carpet is now also in place and the side panels have been covered as well.
Max:
Max inspects the interior and boot before they went back in!
SVA (nearly) ready pictures:
07/09/2007
Gaiters and panels
Hand brake gaiter installed, this was an eBay item made from leather, much nicer than the one that comes with the kit! Do have a nice handbrake handle but it wont pass SVA edge testing so here's a budget rubber hose item for the interim! Gear gaiter installed, may put the stainless ring round here to finish it off. Do have a nice knob to go on here, the donor ones is broken and wont stay on anyway.
Carpet on the side panels at the rear
01/09/2007
Hose, brakes and interior panels
First off some construction pictures, added some new silcon hoses specificially made for the M20:
SVA safe brake line attachment, thanks to folks on madabout kitcars for this tip!
And now some interior shots:
Started work on rear quarter panel covers made from 1mm ali.