Classic Daily 1975 BMW 2002 M42 turbo swap

This project has been in progress or a bit but I am working on getting back to build threads and sharing more what we do. A little history...

1975 2002 with early bumpers Orignally an automatic but swapping to a turbo M42 and a bunch of other fun stuff. This build is one where nothing is being held back. If metal needs to be cut to make something fit better then it is being done.

The car

Original M10

Pull everything from the interior.

Even the sound deadening.

Some rust hiding in there.

Rear subframe out

Out comes the engine

Break down the front suspension

New front struts, H&R sports and billy sports

Reinforce front subframe.

Coated front subframe

Semi boxed rear trailing arms.

UGH rust...

Bottom side in the back cleaned and then re undercoated.

A lot more has been done already but we will leave it there for today. Will continue to update.

So yeah there was some rust in the floors and firewall.....but just got cut it out and weld in new.

drivers side

passenger side

Fit and tack

Getting there...

The firewall was pretty rusty too....again cut and replace.

weld it in

connect the dots

grind grind grind

This is getting a turbo M42 and we are pushing it back a little further than our standard m42 installs.

It's real intake and manifold

mounts (drivers side)

Hard to get a pic of the passenger but anyway....

More to come

I love your projects and you do excellent work!

I like what you did there, (all of it) carry on.

So much win right here

That will make an absolutely wonderful car.

I'm in for this one

Oh yes this will be good.

Ooh, this looks like good fun.

Good progress and at least no rotted out rear subframe mounts

oldtin wrote: Good progress and at least no rotted out rear subframe mounts

Nope those areas are very solid.

Wow. I love it. You do great work.

I'm in to watch this one too!

These little guys are to mount the intercooler at the top. I am trying to make things as hidden as possible so they weld to the underside of the core support.

Terrible picture and not pretty welds but you get the idea...

Some welded in captive nuts at the bottom.

Then bingo a pretty big intercooler in a 2002. (for those 02 guys...you can see there has been a little bit of cutting that took place here to fit things how we wanted)

This car is getting AC as well so next up we need to fit a condenser.

Sandwiched in there

Then pulled out so you can see the upper/lower brackets for the condenser captive nuts to bolt the condenser in.

We are running a disco potato on this build...so Garrett GT28RS (dual ball bearings, blah blah blah)

Time to make it fit...

Enough for now...more coming soon.

Building the turbo manifold

Adding the wastegate connection

All welded up for the most part

Welded the port side..

Sometime on the belt sander

It's hot and humid in the shop today so it's time to spend some time in the AC office and update build threads. It's hard to find time to do everything....gotta try and keep up on them and share. Pictures are a little out of order but will show them by job...

Made these little mounts for the e30 m42 lower radiator bumpers.

Welded in. Notches are to help clear the bottom of the radiator

sits pretty nice

upper radiator mount in progress

I wanted to use an OEM fan from something. This happens to be from a 2010 mini cooper and should fit the bill nicely.

made a shroud to mount it to the m42 radiator.

A little cad work

Some time at the band saw and you end up with these guys

Some welding and more cad...

and...

Will then be powder coated!!

Continuing on...working on the intercooler plumbing

Made this tool to be able to put a bead on the IC piping.

Short one from the turbo to the IC

I'm getting better and better an aluminum....

From IC to Throttle Body

Pulled back a bit

BOV placement

BOV flange welded on

Air filter setup...

This car will have AC so it needed a spot for a drier. Using a e30 drier as it is easy to replace if needed. Small bracket..cad first

then metal

welded in and drier fitted with lower AC line mocked up

Then making other AC lines... had to weld to the 318 compressor fitting and add a crimp connector.

on the car (mock up compressor)

low side mocked up

and welded

Line from drier to evap in car. Fill port comes up from down low.

Low side...this was later changed a bit.

hold downs for everything

All the lines mocked up

Crimped and painted

Inside the car

crimper

crimped

installed

We are using an updated HVAC unit in this car and it required some sheet metal work to make it all fit....

Cut a hole in the firewall (this is where the old fan would have popped out)

Fitting better

Made a mount for it

Mount with box out

tunnel was cut a bit too

Remaking the tunnel to fit

had to make a box to cover up the hole... Start with some cad...

test fit

Then made from metal

Amazing work

What hvac unit is that?

I hope to someday own another 2002. Looks like a great project so far.

Very nice!

Billy_Bottle_Caps wrote: Amazing work

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