- Post is under moderationHARDCORE S54 E30 Thunder from Down Under
SKIN DEEP #S54-swapped E30. Words and photos: Chris Nicholls. They say you shouldn’t judge a book by its cover and Andrew Burke’s home-built, DIY-painted E30 is exactly the reason why.
“Why are you shooting that little thing?” says a passer-by during the shoot. I casually pop the bonnet and see his eyes widen. “Jeez, there’s some work gone into that,” he says, before firing off a few photos on his phone and walking away. This sort of thing happens several more times during the shoot and it’s easy to understand why.
From a distance, this is just another E30 track car. The matt black paint, done as a last resort after troubles with the painter, is hardly the last word in beauty and the stock M Tech II body kit isn’t going to set anyone’s world alight either. No, things only get interesting when you get close. It’s then that you see the custom Forgeline wheels and fat, circle-track StopTechs and imperial-sized AP Racing J-hook discs (chosen because imperial gear is cheaper than metric). Next, you peek inside and notice the #Motec M800 ECU sitting on a custom carbon plate on the floor. And the oil lines for the Peterson dry sump kit running next to it. And the Motec C127 colour dash logger and Tilton pedals. It just doesn’t stop. Finally, you pop that aforementioned bonnet and see the immaculate S54 with carbon cover and CSLreplica intake nestled in-between the strut towers, surrounded by Goodridge Teflon hoses and a Peterson oil pressure primer pump. If ever there was a car to prove that sometimes, the opposite of the idiom ‘beauty is only skin deep’ applies, this is it.
The back story of this Australian E30, as you might suspect given the engineering involved, started several years ago (six to be precise) when owner-builder Andrew Burke picked up this 325is to be a street-registered track day build. Having got tired of risking his E92 335i road car on the track, he thought back to a 1989 E30 brochure he got as a kid and decided that would be a better bet. As most builds do, things started off small. Some H&R springs and Bilstein Sport dampers, rebuilt stock brakes and bolton exhaust, a short shifter and new Recaros did the trick for six months, but one track day at the wonderfully nicknamed Haunted Hills circuit (actually Bryant Park) in his home state of Victoria, Andrew noticed puffs of blue smoke on overrun thanks to some keen-eyed photographers. “That was all the excuse I needed to go ‘Oh, this motor could potentially have some kind of small issue in the next three, six, nine, 12 years, I should probably just swap the engine out right now’” he laughs.
Thus began a long and involved process of finding and fitting a new motor. Having decided a resto-mod approach was best, he settled on an S50 and sourced one from the UK, but all was not well. “As all UK motors are, it was covered in corrosion, all the aluminium bits were all pitted from the salt and whatever other calamities occur over there in the middle of winter, so I didn’t do a whole lot with it other than strip it down to a short block and basically sand blast all the things,” Andrew says. Having cleaned it up, he found it still good enough to use, so left it standard internally and got to work fitting it. On went an E34 sump and 12° angled double-shear shift rod to get the now-twisted stock G250 five-speed to work with the AKG DTM shifter, some custom-made exhaust manifolds from Andrew Nicholls at Meridian Motorsport and a VFT E36 DTM-style carbon air box specifically designed to fi t S50s in E30s thanks to a notch cut into the back to clear the brake booster. To ensure that it all ran, Andrew cut and re-connected the stock harness himself and fitted an Alpha N ECU chip.
However, while he may have cleaned it up, it turned out the engine’s not-so-perfect appearance was rather more indicative of its condition than first thought and sure enough, the number five journal went at a Winton Raceway track day in true S50 style. “A $350 tow truck ride home later [Andrew not having a trailer at the time and Winton being two hours from central Melbourne] we were sitting in the garage, the old man and I, saying ‘Well, we’re going to have to fix it, I guess’”. Andrew admits that even at that point, the idea of fitting an S54 came into his head, but he wasn’t quite ready to quit on the idea of an S50-engined E30 yet, especially having done so much work to make it fit.
Thus, he decided that, rather than throw everything away, he would build a proper race-spec S50 and see what happened. Sadly, it’s here that Andrew suffered the all-too-common “bad workshop experience.”
After searching around for a well-regarded builder, he thought he’d found one in a former Team JPS BMW factory race engineer in New South Wales, but while the specs were suitably serious, complete with 11.6:1 Wossner pistons, Pauter I-beam rods, 296° cams, Supertec Inconel valves and the current Peterson dry-sump system (designed to avoid ever spinning a bearing again), it “never made any real power.” “Without going into too much detail, it just fell on its face above 6000rpm,” he says. Worse still, it didn’t even last that long. A mere 500km of track work later and Andrew was sitting on the side of the Winton tarmac with two holes in the block from a rod and rod bolt respectively, oil pouring out everywhere and his car partially in flames thanks to starting a grass fire underneath it. The worst part? A postmortem found the likely cause to be poor assembly.
“As I pulled the bits off the motor so I could get it out of the chassis, I found one of the ARP rod bolts was poking through the block on the exhaust side. I didn’t see it originally as a result, but it was poking through with all of its threads still intact. So it was not like the bolt snapped – it was like it completely unscrewed itself – and I can’t imagine a bolt that’s designed to be torqued to yield, if it was properly fastened, would have come undone. End of story. So that was that, which was a bit unfortunate.”
Unfortunate indeed, and at around AU$30,000 (£17,000) for the engine, expensive. Andrew adds that figure doesn’t even include the cost of ancillaries fitted to deal with the extra power, the current 8x17” Forgelines, the previous SL6R and SL4R Wilwood calipers and discs (since replaced by the StopTechs because Andrew bought another road/track E30 he wanted to put those on), the custom-built AST two-way adjustable coilovers (again, since replaced by custom MCS two-ways) and several other mods besides. However, Andrew wasn’t prepared to throw it all away, so after convincing his wife he “wasn’t silly,” he pulled the trigger on a mint S54 with just 18,000 miles on it out of a wrecked Californian Z4 M.
Being so new and from California, this motor was in stunning shape. There was no dust behind the water pump or alternator pulleys and even the internals, which Andrew inspected when he pulled off the sump to fit the Moroso dry sump pan, were unvarnished.
Given he had no money to put new internals in it, this worked out perfectly. Plus, the S54 made more power stock than his built S50 anyway, so in it went, with only a Karbonius CSL-replica air box – fitted because the StopTechs meant he no longer needed the booster – a Racing Dynamics carbon engine cover, new custom exhaust manifolds (again from Andrew from Meridian, who by then had moved on to start his own venture called Trackart) and a few other mechanical pieces like an Eisenmann exhaust needed to make it work. At the same time, Andrew realised that to actually run the thing (especially given he was keeping Vanos and drive-by-wire), he would need to upgrade his dash from a set of Stack gauges to a Motec logger to ensure the necessary input and output numbers, and after contacting Jason Ingram at Advanced Motorsport Electrics to do the concentrically-wound, DR25 heat-shrunk harness and install it, he got it tuned by Lee at Melbourne Performance Centre and brought it up to Broadford State Motorcycle Centre for a shakedown, which is where we did the shoot.
His impressions of the car now it’s finished (bar a cage)? “I was thrilled with the way that it handled and the way that it stopped even back when it had the second S50… but I was deeply disappointed on some level that it didn’t make as much power as I was expecting. It was certainly fast enough, but it never felt brutal, I guess. Whereas the S54 is still not crazy by any means, it just feels a lot more angry. It feels significantly more powerful.” Given this first shakedown was conducted at only half-throttle, that’s a brilliant portent and suggests that when this E30 is finally unleashed, its unassuming looks, combined with all that power and handling, will mean the opposition won’t see it coming.
“If ever there was a car to prove that sometimes, the opposite of the idiom ‘beauty is only skin deep’ applies, this is it”
TECHNICAL DATA FILE #S54 / #BMW-E30 / #BMW-E30-S54 / #BMW-S54 / #BMW-3-Series / #BMW-3-Series-E30 / #BMW / #BMW-3-Series-Coupe / #BMW-3-Series-Coupe-E30 / #Bosch / #BMW-E30-S54B32
ENGINE 3.2-litre straight-six #S54B32 , #Karbonius CSL-replica dry carbon air box, #K&N air filter, #Aeromotive fuel pressure regulator, #Bosch-044 fuel pump, #Aftermarket Industries swirl pot, #MagnaFuel dry break billet fuel filters, #NGK-Platinum plugs, Setrab 19-row oil cooler with -16 fittings, Roush Yates carbon catch can, Peterson R4 dry sump pump, #VAC-Motorsports mount kit, #C&V HTD belt drive with VAC/ATI fluid harmonic balancer, -16 feed and return oil hoses, -12 scavenge, #Peterson scavenge filters, -10 pressure feed to VAC Motorsports oil manifold, custom #Moroso dry sump oil pan, Peterson single-stage remote oil primer circuit, Peterson billet four-gallon dry sump tank with custom #CNC bracketing, dual breathers and 100 micron filter screen, Canton billet five micron oil filter on pressure stage, #C&R-Racing oil filter housing with provision for secondary oil cooler circuit in rear of car, #Wix-Racing 51222R filter, Goodridge XF 910 and Brown and Miller (BRMS) Teflon hoses, VAC-Motorsports lights, accessories and alternator pulleys, ATI damper by VAC Motorsports, AKG-Motorsport Group N engine mounts, #Racing-Dynamics dry carbon engine cover, Trackart custom equal-length exhaust manifolds and custom 2.5” exhaust, Eisenmann E36 M3 rear box, Motec-M800-ECU , #Motec SKN dual CAN knock module, Advanced Motorsport Electrics custom concentricwound wiring harness with Kevlar tracers, Raychem boots, Souriau and Autosport connectors
TRANSMISSION #G250 five-speed manual gearbox, #AP-Racing 7.25” twin-plate clutch and lightened cro-mo flywheel from E36 M3 R, AKG DTM shifter, PPF axles, re-balanced OE driveshaft, OE diff with extra clutch packs, Z3 M housing, custom transmission mounts and subframe reinforcements
CHASSIS 7.5x17” ET20 (front and rear) #Forgeline-SO3 wheels with 235/40 (front and rear) Nitto NT-01 tyres, VAC Motorsports 90mm studs, #Motorsport-Hardware cro-mo nuts, 3mm spacers (front), Motion Control Suspension custom two-way remote reservoir coilovers, #Eibach 60mm springs, AKG Motorsport polyurethane, #Treehouse-Racing and custom #Delrin bushes, custom Trackart T45-based cro-mo front strut brace, custom front arb and mounts, Dave Stillwell rear anti-roll bar with custom mounts and reinforcement, full Aurora rose joints, #StopTech STR43 calipers (front and rear), #AP-Racing J-hook fully-floating discs, custom Motorsport Connections Teflon braided lines, Performance Friction PFC01 pads (front and rear), custom-machined 7057 T6 rotor hats
EXTERIOR OEM Tech II kit, custom bi-xenon headlights based on TRS projectors and 3D printed adaptors, rear lights lightly tinted with Diamond black
INTERIOR #AKG-Motorsport Delrin shift knob, AKG Motorsport DTM shift lever and short-shift kit, Alcantara gear gaiter, #Tilton 600 Series pedals, Tilton -4 fluid tank, #Speedflow lines, Tilton billet brake bias adjuster, Tilton fluid bias and balance bar adjuster, #Motec C127 dash logger, Recaro SP-A Kevlar V8 Supercar special edition seat, VAC Motorsports billet rails, Sabelt Ultralight harnesses, Personal Grinta 330mm wheel, Lifeline Group N boss with custom spacer, custom carbon panel behind wheel for light controls, custom Trackart harness bar, custom aluminium scuff plates
THANKS Andrew at Trackart for the exhaust, brake cooling duct, harness bar and strut bar fabrication work, Marcos at Motorsport Connections for the Speedflow bits and hoses, Jason Ingram at Advanced Motorsport Electrics for the incredible work on the harness and Lee Burley at Melbourne Performance Centre for the dyno tuning
Carbon engine cover and replica CSL carbon air box make this S54 even sexier.
Single Recaro SP-A Kevlar V8 Supercar special edition seat.
“After convincing his wife he “wasn’t silly,” he pulled the trigger on a mint S54 with just 18,000 miles on it out of a wrecked Californian Z4 M”
/ #Motec-M800 ECU mounted on custom carbon plate.
Swirl pot, pump and filters mounted in boot.Stream item published successfully. Item will now be visible on your stream.
- Post is under moderationNOTHING IS IMPOSSIBLE 720hp turbo #BMW-E36 hardcore British built M3. We revisit an insane turbo E36, now pushing 720hp. Ignoring conventional routes, Steve Will has created a turbocharged E36 M3 that performs like no other… Words: Stav Neophytou. Photos: Andy Starkey.
While turbocharging in-line six #BMW engines has been the norm in Europe and the USA for decades, until recent years it’s been a rarity in the UK due to our cars being righthand drive. BMW sixes are canted towards the exhaust side, which also happens to be the driver’s side on right-hand drive cars. This means a severe lack of room for not only the turbo and manifold but getting a suitably large exhaust downpipe past the steering column is a real nightmare, too. However, despite these fitment headaches, turbocharging is finally taking off in the UK BMW scene.
A man clearly ahead of the times, though, is UK resident Steve Will. This incredible E36 M3 is his, and it’s been turbocharged for the best part of a decade now! While it’s been a long road, full of pitfalls and learning experiences, the end result is jaw-dropping.
Steve bought this car back in 2005 and turbocharging it was always on his mind since driving a turbocharged 635CSi many years previous. Despite the perceived impossibility of a RHD Turbo E36 M3 back then, it was barely two years later before it had its first incarnation as a turbocharged engine. This first setup used a cast log manifold by South African BMW expert Savspeed, a Turbonetics T70 turbo, and a fully-forged engine with a compression ratio of 9.5:1. Unfortunately, while clearly incredibly powerful, the combination of the high compression ratio, pump fuel and suspect mapping meant the engine expired due to severe detonation while still being tested and mapped at Bruntingthorpe Proving Ground.
Thankfully this initial disaster was covered under the tuner’s warranty, so the engine was rebuilt with a more pump-fuel friendly 8.5:1 compression ratio.
Sophisticated Motec engine management was fitted and the car was finally dyno’d at a ballistic 670hp and 500lb ft of torque. While we really don’t need to tell you how incredibly fast a 670hp E36 is, due to the big turbo and basic log manifold it wasn’t the most efficient setup in the world. In fact, even Steve will be the first to tell you it was actually very laggy. While it hit the 350hp mark at 5500rpm the power then literally jumped up 100hp every 500rpm from then onwards, pulling hard until over 7500rpm. It was an absolute animal; insanely fast but far from controllable!
The engine stayed in the above spec for a number of years but as the car was primarily used as a drift car, both for fun and competition, outright power became less important than response and drivability. So, when the engine finally failed in 2011, plans were made for a more user-friendly engine spec. While the cast log manifold was still seen as the only option, Steve increased the compression ratio to 9:1 and fitted a smaller PT5862 turbo – Precision’s equivalent of the popular Garrett GT35R.
After some expert mapping from Greg at Protuner the way the car drove was transformed, with 350hp now coming at just 3500rpm. At the same rpm the engine was also making well over 500lb ft of tyredestroying torque. Peak torque was incredible, 650lb ft, and response was instant, too. Compared to the original larger turbo, however, peak power was down over 100hp at 560hp, and peak rpm was much lower, too, with the graph flat-lining from 5000rpm until just over 6000 when it started to drop.
There’s no doubt 560hp and 650lb ft are supercar-smashing numbers in most people’s eyes, and if Steve knew no differently he’d no doubt be over the moon with the performance but despite the amazing torque and response, his previous experience of having a huge 670hp and a screaming high rpm performance was impossible to forget. In fact, he was so used to the insanity of the old setup he called this one “boring”, which leads us to where we are today…
What Steve ideally wanted was the best of both engines: the insane power of the big turbo engine but with the torque and response of the small turbo engine. Pretty much everyone he spoke to said that was impossible. Undeterred Steve employed the services of someone who sees the word ‘impossible’ as a challenge: Thomas Zurawski of Zurawski Motorsport in Ledbury, Herefordshire.
While the engine itself was bulletproof, and it’s hard to beat a #Motec-M800 ECU, Zurawski Motorsport is an expert in custom turbo setups and could see the existing design left a lot to be desired. Not only was the cast log turbo manifold considered a poor design but the inlet plenum, intercooler, exhaust system, and air filter setup were all on the list for improvement. Tubular twin scroll turbo manifolds didn’t previously exist for RHD BMWs due to the lack of room but the Zurawski design fits perfectly. And not only does it flow far better than a restrictive log manifold but the twin-scroll design drastically improves turbo spool up, allowing a bigger turbo to be used without losing drivability.
To further aid spool and throttle response, twin WRC anti-lag valves have been fitted, allowing huge amounts of airflow to go direct from the compressor to the exhaust manifold which, along with fuel and ignition adjustments from the Motec ECU, give the engine the ability to stay at full boost even when the throttle is closed, not to mention the rapid-fire bangs and huge flames from the side exit exhaust!
The other big change to the engine is certainly the most controversial: the inlet plenum. The shape and design of it is certainly a world away from typical designs and, due to this, many naysayers claimed it would be restrictive or simply not work. The reality is, however, it’s actually a commonly-used design in turbocharged race engines, as found in WRC, RallyCross, and LeMans. The unusual design gives equal airflow to each cylinder, something that’s a big problem on turbocharged cars, especially on in-line six engines, and by allowing the cylinders to receive equal amounts of airflow improvements are seen in power, spool up, reliability, and to safe boost limits.
In addition to the manifolds, the entire turbo system – from air filter to exhaust tailpipes – was custom-made from scratch by Zurawski Motorsport for maximum flow and efficiency. It includes a huge grillemounted air filter, an enormous intercooler that necessitated the rear mounted radiator conversion, twin external wastegates, and a full custom exhaust system, with a very cleverly designed downpipe that somehow manages to snake past the dreaded RHD steering column!
Of course, the most important part of any turbo system is the turbocharger itself, which is a BorgWarner S300SX 9180 turbo, with a twin scroll T4 turbine and billet compressor. This turbo is actually bigger than the previous original laggy unit, so surely this new engine can’t be very responsive? Think again…
With the car once again in the expert hands of Greg at ProTuner, the new setup made a touch over 600hp at just 1bar boost, and 700hp at 1.5bar, 30hp more than the traditional-style turbo setup using the log manifold. While the power is impressive, what really makes it special is this time he also had an insane 730lb ft of torque, with over 500lb ft of that by just 3700rpm. Yes, it spools as fast and makes even more torque than the small turbo did but makes more power than the big laggy turbo! The currentspec engine actually makes more power and torque than the original engine right across the rev range, from 2500rpm until over 7000rpm. In fact, at 4000rpm it now has 375hp and 490lb ft more!
Buoyed on by these incredible results, the car recently returned to the dyno with 109 Octane race fuel where it made 720hp and over 800lbft at 1.4bar boost. The new fuel gave such incredible response and torque that, by the time of writing at least, Steve’s been unable to get traction at any higher boost than that. Once he finds a traction solution, though, he’s hoping for 800hp plus. Considering the current results, even over 1000hp looks to be easily achievable with only a slight increase in turbo size.
While we make no apologies for concentrating so much on Steve’s groundbreaking engine, the rest of the car is no less wild, both in looks (thanks to the M3 GTR wide bodywork and Team Dynamics motorsport wheels) and in performance (thanks to a spec that is truly world class).
On the inside there’s a comprehensive custom roll-cage that ties in to the diff mounts, a sophisticated rear mounted radiator setup that draws air through the side window ducts and exits via the rear diffuser, while underneath there’s a drift- specific front suspension design with incredible amounts of steering angle.
What’s perhaps most impressive is the thought put in to all the various parts fitted to this car. While you will no doubt have read the comprehensive spec list and recognised most of the parts’ manufacturer names, Steve has built this car more like a Works race car than a typical privatelyowned car, with the reliability and strength of all components being the primary consideration. This doesn’t just mean strong and effective parts but even things like the fuel and oil pressures are continuously logged by the ECU, which shuts down the engine if something deviates from the specified parameters.
So now the car is complete, what does Steve want to do with it? Well, despite being used for competition drifting for some time now, he’s more interested in just having fun in it without the stresses of trying to win trophies. On the rare occasions this car isn’t on masses of opposite lock, Steve’s actually very keen to take it back to where the original turbo engine expired, Bruntingthorpe Proving Ground, this time to break the 200mph mark – something it should do with ease.
For a car built with nothing but Steve’s own enjoyment in mind, the progress of this build over the years, and especially the final result, is a lesson for all of us. Not only is this sort of unbelievable, best-of-all-worlds, engine performance perfectly possible (and reliable if done correctly) but putting true thought in to what you are doing, taking influence from world-class race cars rather than simply following the crowd, really pays off in the long run.
The rest of the car is no less wild, both in looks and performance.
DATA FILE Turbo #BMW-E36 / #BMW-M3 / #BMW-M3-E36 / #Motec / #BorgWarner /
ENGINE 3.2-litre straight-six #S50B32 / #S50 / #BMW-S50 , standard crank, #Pauter steel rods, 9:1 JE forged pistons, Cometic multi-layer head gasket, ARP head and rod bolts, standard head and cams with #Vanos enabled, #Motec-M600-ECU with an E888 expander, #Zurawski-Motorsport twin scroll tubular manifold, twin Turbosmart external wastegates, #BorgWarner-S300SX-9180 twin scroll T4 turbo with uprated billet wheel, full turbo-back Zurawski Motorsport exhaust system with side skirt exit tailpipe, twin WRC-style anti-lag valves, heat wrapped turbine housing and downpipe, #Zurawski-Motorsport equal flow inlet plenum, custom boost pipes and front mount intercooler, Zurawski Motorsport grille mounted air filter, high flow fuel lines, high flow alloy fuel filter, twin #Bosch-044 fuel pumps, 25ltr ProAlloy fuel cell, uprated fuel pressure regulator, Titanium oil catch tank, switchable ECU maps for Shell V-Power and Sunoco race fuel, switchable anti-lag and launch control systems, #Mocal oil cooler, uprated engine mounts, custom rear mounted radiator system, additional electric water pump, full fire extinguisher system, interior and exterior emergency cut-off switches, Petronas 10W60 oil. 720hp and 800lb ft
TRANSMISSION #ZF five-speed gearbox, #Helix twin-plate paddle clutch, custom lightweight steel flywheel, M3 Evo rear diff with shimmed LSD plates for 70% lock, E46 M3 crownwheel and pinion, uprated gearbox mounts, #ATF Racing gearbox, diff mounts integrated into roll-cage
CHASSIS 9x17” (front) and 10x18” (rear) #Team-Dynamics 1.2 wheels with 225/45 (front) and 265/35 (rear) Pirelli PZero tyres, BC coilovers, IRP drift front suspension setup, lightweight alloy adjustable lower arms, rosejointed lower arm bushes, custom adjustable top mounts, Mocal power steering cooler, polybushes, standard M3 brakes, hydraulic handbrake, Wilwood incar brake bias adjuster
EXTERIOR #BMW-M3-GTR front bumper, front wings and rear spoiler, E46 M3 GTR-style vented bonnet, custom rear arches, custom alloy rear diffuser, roof vent, rear window ducts, #Plastics4Performance lightweight windows
INTERIOR Full custom FIA-approved multi-point cage, Motordrive bucket seats, TRS harnesses, OMP steering wheel, Stack AFR, EGT and oil pressure gauges, Autometer boost gauge, carbon doorcards, custom ducting and shrouding for the rear mounted radiator
THANKS A-Frame Engineering (www.aframeengineering.co.uk), County Alarms (www.countyalarms.co.uk), ProTuner (www.protuner.co.uk), Zurawski Motorsport (www.zurawskimotorsport.com)
Steve wanted the power of his big turbo engine but with the torque and response of his small turbo engine.
Everything about this extreme E36 M3 means business. Side-exit exhausts look and sound awesome. Custom alloy rear diffuser allows hot air to be pulled away from the boot-mounted radiator, itself fed by pipes attached to side window intakes.Stream item published successfully. Item will now be visible on your stream.