My GKD Legend Kit Car Build - May 2009 until ...

[Richard]

Stop motion pro is a good program to work with your webcam.. You can set regular time intervals for the pic's to be taken then will stitch then together for you...

Thanks for that Bri, will check it out when I get a moment.



On car front, been lining up aluminium panels and checking fit. A few small deviations spotted and edges are a bit too rough for my liking so not laser cut. Various sanders and grades of paper out and a little tidying up going on. Some of the welds are a little lumpy (I suspect I am being fussy) so just sanding them back a little to get a better alignment, what is a bit anal is that this is on the bottom of the car !   

Sanding the edges is going from 180 grade to 400 and then 600, not sure if that is best thing to do but it seems to be effective if then buffed afterwards. happy to take any advice or opinion.

[Richard]

Short update.

Panels all seem a good fit, been aligning them for hole marking and drilling underneath while things upside down, a little bit of tinkering needed on drivers floor pan where it was a little to big.

Started the great bushing squeeze, the old plumbers washing up liquid tip to the rescue. did have the entertainment of watching the odd pushed in bush squeeze itself back out again, this seems to happen when you've not got them equally spaced in their housing.

So slow steady progress, should flip the chassis the right way up again in next day or so.

['The Gaffer']

Keep up the good work Richard.

I know you have help but dont forget if you need a extra pair of hands just give me a shout.

[Richard]

Sure, not really getting a lot of time to progress so its being done in little bits, hence the slow progress.

Got the templates made up for the rivet spacing for IVA, one lot at 50mm and other at 25mm, makes it easier to line up, just clamp them in place and drill in holes, well that's the theory

['The Gaffer']

I know where theres a nice Cobra for sale to tide you over, only joking

[Richard]

Really ?  Where is it then ?   


Having a fight with those rear bushes !!!

My vice isn't up to it so I think it is a short trip to the forge for a favour, well a few pounds anyway, anyone got a bench press handy ?

[Richard]

A bit more progress today, not spent long and got a few bearings in place.

Seems a few rules and principles involved here that novices like me don't know but you pros do.

Got a good little tip from Pete in between breakfasts this morning, thanks for that it helped along with the other principles !! 

Chassis goes right way up later in the week, and then will be rolling.

Having a few extra paint design thoughts, note to self, must learn to air brush paint.

['The Gaffer']

Keep those updates coming Richard.

[Bulldog Bri]

Sounds like it's coming along nicely Rich... Post a pic or 2 of the rolling chassis when it done...

[Richard]

Will do a mini pic post update and refresh in the gallery in next week or so, it is more than overdue.

One thing that I'm finding is that building appears to be a more easily done task than pulling apart donor car. This may of course be because I've yet to get to the tricky bits  .

All wheel bearings now done, back to those rear bushes next. I would recommend that if anyone else is contemplating building and there is an option to have the bushes pre-installed it is something worth having done if you don't have a well equipped garage ! Still going to get it done now I've started, I want that lining up to be as good as possible.

[Richard]

Plugging away.

Bushes all in now 

Design of wishbones makes this tougher than it initially appeared even with a bench press.

Had springs arrive yesterday, front ones were not a pair, seems a "special order one" got included by mistake, will now have to wait for postal exchange before progressing there.

I really must hurry up or I'll miss this lovely hot sunny BBQ summer !! 

[Richard]

Only a little progress last few days, been catching up on chores.

Clamped side panels in place, a little tinkering but not much, appreciate the simple build here, so far a lot easier putting together than taking the donor car apart, however a long way to go yet.

With the 6 cyl Legend now being offered it will be interesting to see who picks which one. We're obviously on the 4 cyl model and as a first build it is going alright, I think having the encouragement of the club helps and well recommended.

['The Gaffer']

It will be great to see you on the road Rich. Keep up the great work!!

I was only thinking at the meet, it would be nice if a few of us gave you a quick spin in our cars to keep the 'this is what its all about feel'.  Got a bit dark for me at the last meet though .

[Richard]

Had springs arrive yesterday, front ones were not a pair, seems a "special order one" got included by mistake, will now have to wait for postal exchange before progressing there.

I really must hurry up or I'll miss this lovely hot sunny BBQ summer !! 

Seems I was showing my beginner status !!    Rear springs same length / size and same writing on them, front ones not same size one one 1cm longer than other and numbering looked different, however, they are the same apparently     so there you are an embarrassing mistake on my part. Still I'm expecting a few of these types of error on my behalf.

Always learning.

['The Gaffer']

That does sound a bit odd.

How can they be the same if they are different lengths and have different numbers, can you double check?

Just dosent ring true with me sorry.

[Bulldog Bri]

Not completly sure, but as the rear of the car doesn't carry quite so much weight, they are a softer rating damper but longer travel alowed in the shock. The set I have on my 7 are shorter for the front

just a thought.

[Richard]

rear pair were identical front different pair but not a pair or so I thought, will post pics when I get on a device with the photos on.










Now this is where I was a bit naive, as the springs were clearly a different length no just by a couple of mm either and the writing on the one on the left could be read as 360 or a wonky 350 I thought them not a pair.

As said above I am wrong, I did end up wrapping up carefully in a shoe box and posting off.

Obviously once compressed it is the physics forces that count but just didn't expect the difference in the physically to be noticeable to that extent. live and learn - I can hear the more experienced perhaps smiling at this novice mistake.

On the dampers I have reviewed the graphs and they are fine. I have the basic starting set up to file for much later.

[Richard]

Aha - Appears I am more sane than I've been thinking !

Pair of springs on their way to me and I'll need to find another shoe box or something to post the other one back.

This should not be an excuse for anyone in my household to rush out and buy more shoes !!! 

['The Gaffer']

Glad you got it sorted, appears you were given duff info.

[Richard]

I think this is a lesson in communication and perhaps a defensive nature of someone who thinks they are being criticised.

I should have paid more attention to detail and so should Damper specialist and GKD, never mind all sorted now in theory, I await package. Teething troubles this one.

What is better is that perhaps I am not insane after all and all those comments by people down the years are wrong 

[Richard]

Early pic of chassis lying on floor.

['The Gaffer']

Let me guess, you've sat in it right?

[Richard]

Let me guess, you've sat in it right?

No I haven't, in fact I don't think anyone has. Seats are inside the house in a box and a very brief sit in one of them has happened.

[Richard]

Replacement proper PAIR of springs arrived, yippeee.

The boys in this household are getting weak they can't compress 350lb springs between their hands !

Hopefully a bit of time this evening for another tinker.

['The Gaffer']

The boys in this household are getting weak they can't compress 350lb springs between their hands !

Ha, lightweights

Good you got the right parts now

[Richard]

Been a long time for an update, not sure if anyone really noticed 

Lots more traveling been done so not as far as I wanted to be so I guess those late night are coming up in the garage.

Suspension is all put together and went in quite easily, the front springs are right on the limit of needing to be compressed to go on, so one of those little phrases of "ease on".

Front all built to a stage I could put on the wheels but I've resisted doing that. A little padding needed in places with washers without making certain parts to tight, was quite impressed that the two sides were very even in the gaps. I did need a couple more washers so picked them up on a visit to Beaulieu for the massive classic car part event.

Rear suspension built but not to the stage of being able to put wheels on.

I did get a phone call from Peter at GKD who told me there was a machining error on part of the rear uprights. A little frustrating but to be fair Peter did contact me immediately he had found the problem and had a way to correct that meant I wasn't too inconvenienced.

Pedal box and associated parts all put together a couple of holes needed a little filing but to be expected somewhere I'm sure.

A few other little jobs done.

More cleaning of old parts needed before going much further, I may being a little too fussy but nowhere near perfect in my view.

A visit to BMW will happen soon to order the new bolts to replace all the key ones I've removed in doing this, something recommended if you were maintaining the original car so this is no different.

['The Gaffer']

Been a long time for an update, not sure if anyone really noticed 

Actually, I did . Been wondering how you've been getting on.

Keep up the good work.

[Richard]

Another little update.

A bit of slow progress, however a few bits coming together.
Finally got a Small Case LSD solution. Worth noting a little problem has turned into a better solution here.

The problem "The Propshaft Clinic" went bust with my prop, so now I don't have prop and it has not been modified. This has lead to GKD doing a different solution which is actually better for all future Legend 4 and 6 purchasers. The props will in future not be exchange but will be made purposefully.

One of the big advantages of the prop set up is that you'll be able to use either the small case LSD or the medium case LSD from donor cars. This means that from the E36/E46 you can source an LSD from any that had it and they are much more common in the 6 cyl cars, the fact that the medium case is slightly longer than the small is accommodated within the prop design, this leaves the half shafts being from the right source to fit, a much easier future proposition.

The items coming together in this chassis are fitting very well, and where a tiny bit of refinement is needed GKD have taken that feedback into the next chassis out the door, overall a very good near plug n play to date.

Off into the garage this weekend for a little bit more progress but hours available are under pressure from the house decorating before Christmas, something I'm sure we've all come across 

['The Gaffer']

Its really good that your feedback will help future builders

Keep us posted.

['The Gaffer']

Nearly a month and no update

Hows it going Richard? Is your car destined to become a rusty pile of bits

[Richard]

Sorry, got very very busy with work, collecting more of those lovely airmiles and hotel points and doing loads of hours. On top of that been trying to get a some progress on some rooms in the house that have no heating.

That aside, I can see the end of this recent burst of activity and a space for time in the garage tinkering. Quite a few things are ready now for putting together so hopefully each hour will see a bit of progress.

Will post an update in a couple of weeks when a little burst of activity should have happened !

['The Gaffer']

Rooms with no heating come first buddy. Look forward to your progress update though

[Marc_NL]

Rooms with no heating come first buddy. Look forward to your progress update though

Why? There is no need for heating in rooms when you are working in the garage 

Also, always ready for an update....and pictures 

['The Gaffer']

Why? There is no need for heating in rooms when you are working in the garage 

Also, always ready for an update....and pictures 

Haha, welcome to the forum Marc

Not sure Richards family would agree with you though

[testingtesting]

Hi,  Great thread,  I'm looking at building one too but using a 3.0 m3 motor. 

Can I ask how much you paid for your LSD?  I've had a look at a snippet of the build manual and it seems very good,  especially compared to some others i've seen!

how have you found it?  Do you get good support from peter?

[Richard]

Hi testingtesting.

LSD's vary in cost second hand. you can very specific ones made of course and several standard special builds are available from the US.

There are 2 sizes used in E36s with the small case only being found on the 4 cyl cars and as far as I know they were an option on the 318is version so they are hard to find but typically over the last year you see them go between 175 and 325 depending on the interest. quite frequently 250 seems to be a threshold for the more popular ratio'd ones.

With your 3.0 M3 you should have an LSD already.

The 6 cyl cars had the medium sized diff and so had different length half shafts to the small case. If I recall correctly they are different again on the M3 and you need to check them for the track size on the 6 cyl Legend. If you need to swap the half shafts for those of say a 325/328 then they are typically available for about £30 each give or take a bit.

Do check with Peter on the M3 LSd / half shafts.

Have to say Peter has been very good so far on the occaisional query and discussion about things for the future on the car. He has been responsive and if he can he'll reply out of office hours as well.

the build manual is a mystery to me as we started before he'd produced one, so a few changes will be going into the original thoughts as a result of what we've been doing.

Ratio's on LSDs vary quite a lot across the BMW range and some are more desirable than others for usual BM track cars and road tweaked cars. Use the link to various calculators and spreadsheets on this site to work out the range you'd prefer to look out for. Some ratios are more readily available.

[Richard]

To pick up on your welding question on your intro.

The welding has been pretty impressive, not quite up to the falling coin stack on the better bike chasis's  but solid enough, in a few places there has been a little welding in the way of washers fitting back cleanly but this is not a big issue. The symmetrical nature lengths and gaps have been very good.

The 6 is a slightly bigger structure in the front and like the 4 a different mix of sizes and shapes are used.

[testingtesting]

Hi,

Problem is the m3 diff doesn't 'hang' the same so I've got to use a none 'M' diff/drive shafts etc etc.

I've ordered a kit now, pick up march time.  Found out that e36 325i diff's are the same ratio as the 3.0 M3 one  so sorted there.  Just in the process of getting together the bits I need from a donor, Looking at £200ish for uprights/calipers(m3's are the wrong fitting)/diff/hubs etc.  For drive shafts I'll buy new ones as there £70 each new or atleast £35 from a scrap yard, with the m3 motor I'd prefer the piece of mind.

All things being well when I've sold off the bits from the m3 that I can I should have all the donor parts and the m3 engine/box/loom for about £500 tops which works out quite well for 300bhp!

Richard does seem very good on the phone and he's assured me the build manual will be finished by the time I pick my kit up.

[Richard]

Ah, the previous model one side rear mounting plate then ?
If so, you can swap the mounting plate for one from the E36 and it will fit  .

I'm not sure all 325's had a slipper but sure you've found that out, yes they had same ratio as standard. The 328 / and later M3's had different ratios.

That is a good price to get that lot for !!

[testingtesting]

well, ended up with a 325i (none lsd) diff
328i calipers/hubs/uprights/rear disc flange for £200.

I'm hoping when I take the m3 apart I can fit it using the 325 diff's drive flanges... I'll keep you posted.

If not I'm not too fussed and can't afford to buy a LSD for the 'normal' diff.  Roll on march!