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      02-08-2021, 06:14 PM   #1
Rallysmurf
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I was going to log the build here or grassroots motor sport, I think here is better for the areas I will have to overcome to finish this in a year.

I would like to make https://rally.100aw.org my first event in 2022!

Why I chose the e82 platform:
wanted a car that would be viable for parts and technology for years to come. Most bmw rally cars are e36 platform. Debated a 318ti m52 motor swap but wanted more turn key. Small, 6sp, lightish, and reliable. 128i was it.

There is one other racing from Colorado, few in Europe, and a e90xi. I'm not the first by no means.
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      02-08-2021, 06:24 PM   #2
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So the car search began....

High miles was fine. Manual a must. Best would be a slicktop as the sunroof has to be taken out. All that was a hard ask for $5k.
eBay, Search tempest, FB marketplace, OfferUp, and Craigslist scouring. FB wins. Found a manual 200k that needed a water pump in DFW listed at $4500. The guy was way over his head he got it at auction and was the third owner. Electric pump he said? $400 he said? He didn't want to touch it. I ended up getting it for 3k!
Now how to get it home to New Mexico? Turn out there was a guy delivering a race car from AZ to DFW and had an empty trailer return. $500 and I had it delivered.
Fixed the water pump and reset the codes all good. Running great!
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      02-08-2021, 06:37 PM   #3
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I met this guy at an SF Bay Area C&C back in 2019.

Looks and sounds like a lot of fun.







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      02-08-2021, 06:43 PM   #4
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Nice! Another one, did you get his name? I might pick his brain. That looks nicely done. Is it wasn't for the small brakes stock it would make it a lot more work, as all gravel rally cars run 15" wheels.
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      02-08-2021, 07:05 PM   #5
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Front Suspension •

So I am looking to increase the strut/shock travel to 7". There is complete kits from samsonas that run ohlins internals or Reiger, but cost as much as I have in this car. I want at least a 40mm front strut so that eliminates most everything cheep. Not that they would have the travel I need anyway.

So the only real option is to build from parts and adapt from other makes.

Front Struts:
As most know rally is huge in Europe. That's where all the quality cheep parts come from. I ordered 7" 40mm adjustable group4 inserts and strut tubes from the motorsports tools from the UK.
Nice this is the strut tube bottoms are 52mm same as 128i knuckles. We will see how close they really are when they arrive. 2.25 coilovers
12" springs hoping they don't bind. Might have to have a helper in there as rally cars run a lot of droop.

Top hats/camber plates I'm still looking. Like GC but also the Vorahlag. Need something with radial bearings and as thin as possible. Am I missing anything else made like that?
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      02-08-2021, 07:23 PM   #6
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Quote:
Originally Posted by Rallysmurf View Post
Nice! Another one, did you get his name? I might pick his brain. That looks nicely done. Is it wasn't for the small brakes stock it would make it a lot more work, as all gravel rally cars run 15" wheels.
He's in my phone as "Mike RALLYE 135i", but I haven't heard from or seen him since COVID hit.

FWIW, E87 116i and others have 284x22 fronts rotors with ō54mm calipers. 280mm rears.
You might gain a few mm of clearance and I'm sure you could still lock them up on gravel. TBH I have no idea how tight 15 inch rims would be.
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      02-08-2021, 07:29 PM   #7
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I did find this post on 15's.

That's what got me started about thinking
About 128i's.

https://www.1addicts.com/forums/showthread.php?t=920790
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      02-08-2021, 08:28 PM   #8
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Quote:
Originally Posted by Rallysmurf View Post
I did find this post on 15's.

That's what got me started about thinking
About 128i's.

https://www.1addicts.com/forums/showthread.php?t=920790
Reading that I'd guess the the 284mm fronts would help some, maybe no grinding. But then again, grinding's not that big a deal. Hell, it's a rally car.
Grinding's almost required.
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      02-09-2021, 02:00 PM   #9
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Rear Suspension•

The biggest two things with the multi link on the e90/e82 to get more wheel travel freely is all the pivots resistance to rotating. I have read there the twisting of all those rubber bushings actually ramp the spring rate as much as 200 lbs. People "tune" the progression they want by installing different amounts of group n bushings.

I want my spring and bump stop to do what they are intended for. I also want free movement throughout the whole travel.

Lots of choices on adjustable arms. Some look like they have spherical bearings but are still actually rubber. LOTS are fragile looking, most all are aluminum. If you want durable which I do, moving to drift parts is a good choice. I found a company with all steel large diameter spherical bearing adjustable arm is a set of 3 pairs for the rear from http://born2drift.co.uk for a really good price. They also have a great looking short shifter.

Second is availability of different rear shocks and later coilovers. That really requires a shock with an eyelet on the bottom. In comes the e90 m3 aluminum lower arms. I got a set of used ones off eBay for $150.

When all this comes in I'll put it down me and report on the freedom of travel.
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      02-13-2021, 11:13 AM   #10
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Shocks and springs •

For rally I want a higher ride height, 2" , as well as up rated spring rate and damper valve rates.

Nonexistent purchase unless you go full race setup that would cost as much as my car.

Not an option for me at this time. Soooooo,
Thanks to eBay and sellers listing quality used parts, makes this a lot easier. Here is what I came up with.

Bilstein HD. as long of stroke as I could find. What I found was older Porsche uses longish shocks. And due to the 40/60 rear weight the valving will be up rated also. These are 993 b6 HD. 7" stroke.

Springs •

For now I am keeping OEM spring location
So my choice here was e93 328i convertible rear springs. Should be about the heaviest OEM
spring.

My springs are m sport they have 8 coils at 13.4mm diameter.

E93 vert are 9 coils with a diameter of 14.5.
That should get me the 2" of lift I want.

We will see. It's a start. The shocks are threaded and when I cage it I'll be going coil over.
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      02-13-2021, 12:48 PM   #11
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You might look at KMac Camber Plates....

This is gonna be fun watching! Good luck.
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      02-13-2021, 07:06 PM   #12
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Quote:
Originally Posted by SKI-R View Post
You might look at KMac Camber Plates....

This is gonna be fun watching! Good luck.
Yeah, m bit sure what to go with as I really do t know my final strut length. Have to see how much room I have.

I'm trying for 2" lift so I don't know where it's going to be.
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      02-14-2021, 09:42 AM   #13
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Finally someone is doing what i wish i could. I canít afford to do actual stage rally but we have rallycross locally and Iíll be borrowing some stuff from your build for that Iím sure.

If you need a little more lift in the rear, these spring pads are thicker than stock and should give you a touch more height.

https://www.ecstuning.com/b-genuine-...33531094754kt/
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      02-17-2021, 12:29 PM   #14
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Did you look at the camber plates from born2drift? Not sure how they compare thickness wise with the other but the look like decent quality.
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      02-17-2021, 04:49 PM   #15
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Rear spherical rod end arms are in from the UK!
9lbs worth!! Http://www.born2drift.co.uk

Stoked on the brute strength represented.
Steel adapters also. Ready for years of abuse.

I ordered some rubber boots to keep them fresh.

Also have a 3.7 diff from THE AUTO e82 coming as my manual is 3.2.

See how that feels before I invest in a LSD.
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      02-17-2021, 08:15 PM   #16
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I might have to get some of those if they’re not too bad on noise or nvh. Still have to street drive my car. Also, once they’re back in stock.
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      02-18-2021, 10:00 AM   #17
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Quote:
Originally Posted by Rallysmurf View Post
Front Suspension ē

So I am looking to increase the strut/shock travel to 7". There is complete kits from samsonas that run ohlins internals or Reiger, but cost as much as I have in this car. I want at least a 40mm front strut so that eliminates most everything cheep. Not that they would have the travel I need anyway.

So the only real option is to build from parts and adapt from other makes.
Interesting project. Thanks for sharing a build thread.

You have probably considered this, but more travel will probably mean your brake flex hoses will need to be lengthened to avoid overstressing them at full droop. I have had good luck with Techna-Fit hoses. Techna-Fit is easy to work with when it comes to custom configurations and are reasonably priced. They built my custom AP front hoses, providing me with an un-crimped sample initially so I could sort out the banjo fitting clocking angle, and them making me a couple of sets once I had sorted that out.
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      02-18-2021, 05:00 PM   #18
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Quote:
Originally Posted by skylarhagler View Post
Did you look at the camber plates from born2drift? Not sure how they compare thickness wise with the other but the look like decent quality.
I didn't. So many variations I think I want USA made for easy parts.
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      02-18-2021, 05:04 PM   #19
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Quote:
Originally Posted by fe1rx View Post
Quote:
Originally Posted by Rallysmurf View Post
Front Suspension •

So I am looking to increase the strut/shock travel to 7". There is complete kits from samsonas that run ohlins internals or Reiger, but cost as much as I have in this car. I want at least a 40mm front strut so that eliminates most everything cheep. Not that they would have the travel I need anyway.

So the only real option is to build from parts and adapt from other makes.
Interesting project. Thanks for sharing a build thread.

You have probably considered this, but more travel will probably mean your brake flex hoses will need to be lengthened to avoid overstressing them at full droop. I have had good luck with Techna-Fit hoses. Techna-Fit is easy to work with when it comes to custom configurations and are reasonably priced. They built my custom AP front hoses, providing me with an un-crimped sample initially so I could sort out the banjo fitting clocking angle, and them making me a couple of sets once I had sorted that out.
Thanks for the tip. I'm sure I will be needing to.

So much unknown but for me that's the fun part. I'm excited about the back end I have about all the parts I need.

I'm thinking of keeping the OEM trailing arm for something to break away on a big impact.
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      02-18-2021, 07:48 PM   #20
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Damn. This is a great thread! Am enjoying following it.
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      02-19-2021, 08:30 PM   #21
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Front Suspension studies.

Found this e46 rally strut.

It's 65 mm!! Inverted.
190mm of travel And Will lift me 40mm.

It's single adjust that might just make a real rally strut affordable!

They are made by https://instagram.com/spectrum_suspension
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      02-24-2021, 07:15 PM   #22
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Of course I could afford the $1600 strut above.

So,

AVO single 7" travel 40mm struts came in from the UK. OEM m sport strut travel is 4.25"!

52mm lowers fit no problem. Getting a helper and 10" main spring coming.

Still flopping on what plates for the top....

Thinking ground control street.
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