Dan's 2nd E30 Build

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straight6pwr
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Re: Dan's 2nd E30 Build

Postby straight6pwr » Wed Jun 15, 2011 8:31 pm

headlights are installed! heres what all was finished:

Finished sealing up the projectors with aluminum foil tape:
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The headlight bucket had to be slightly trimmed to fit one of the brackets I added to secure the projector.
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Install into the bucket:
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Installing the lights into the car

Take out your headlights and the plastic sheilds on the back:
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Get your harness and your beer ready:
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Installed the ballasts behind the headlights. There are big ass ballasts, but they fit along side just fine
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Heres where I attached the harness for the main power (13V constant as shown with voltmeter):
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And the ground:
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Neatly run the harness down the engine bay:
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Seal up the relay to keep water out of it as it ends up by the ballasts/headlights:
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Run the plug for the drivers side across the body with the other factory wires which cross behind the front valance right under the grill:
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Heres all the plugs youll end up with for the lights. This is everything except the city light (if you have euro-spec lights)
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Headlights installed:
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Aiming the headlights:

Draw your diagram (or use tape if you dont want to deface someones property) according to http://www.danielsternlighting.com/tech/aim/aim.html
The cross is the exact location of the lights on the car, the bottom line is 2.1 inches below and is where the cuttoff should land.
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Back the car up 25ft
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Where the lights landed before aiming
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Headlights aimed properly.
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Very happy with how bright they are. Whatever flickering that was happening when first tested is gone. Will post some output pictures when I get the chance.
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ponycarman
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Re: Dan's 2nd E30 Build

Postby ponycarman » Wed Jun 15, 2011 8:57 pm

Nice work man! Looks great!
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Re: Dan's 2nd E30 Build

Postby ss45466 » Wed Jun 15, 2011 10:43 pm

Very nice! Might have to do this someday. :D
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Re: Dan's 2nd E30 Build

Postby M20_fever » Wed Jun 15, 2011 10:49 pm

great upgrade, makes me want to rebuild mine.
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straight6pwr
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Re: Dan's 2nd E30 Build

Postby straight6pwr » Sun Jun 19, 2011 5:51 pm

drove it in the dark on Thursday night, need to aim the lights a little higher. my driveway must be slightly off level. anyways, these lights are amazing, my girlfriend was driving in her car behind me and was like, yeah the other cars around dont need headlights, yours lights up all 3 lanes.
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Re: Dan's 2nd E30 Build

Postby glucklich21 » Sun Jun 19, 2011 7:49 pm

Great link you posted there!
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Re: Dan's 2nd E30 Build

Postby Court M3 » Mon Jun 20, 2011 5:15 pm

nice upgrade might have to do the same with my euro lights
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Re: Dan's 2nd E30 Build

Postby straight6pwr » Sat Jun 25, 2011 11:14 pm

Did some work today. Swapped to a 3.25LSD and finished up the sway bar fix. had Pat at Kummrow weld up a new tab the other day, so when I had the LSD out, it was the perfect time to get the sway bar bolted back in.

Bolt up new bracket and drill holes accordingly.
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Bolt on. It is a tight squeeze, especially with this particular sway bar which is too short before it turns 90deg at the ends. Lots of cursing here.
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The diff swap:

Jack car up (look at those tonka trunk sized tires!)
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PB Blaster is your friend. Coat EVERYTHING.
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From left, and the order which they get removed: 12 axle bolts, 4 driveshaft bolts, 2 upper rear subframe bolts, 2 upper front subframe bolts, bushing bolt.
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be a man and drop the diff without the jack! (sandbag works great to catch it)
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replacement LSD ready to go in.
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Installation is the opposite of removal, only faster!
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Re: Dan's 2nd E30 Build

Postby M20_fever » Sun Jun 26, 2011 3:44 am

Never seen a sway bar go in like that, pretty neat. what ratio diff did you swap out?
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Re: Dan's 2nd E30 Build

Postby straight6pwr » Sun Jun 26, 2011 4:22 am

M20_fever wrote:Never seen a sway bar go in like that, pretty neat. what ratio diff did you swap out?


3.73 came out. its too much gearing with the e36 transmission. great torque, but cruising the hwy is 4200rpms.
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Re: Dan's 2nd E30 Build

Postby straight6pwr » Sat Jul 09, 2011 6:10 pm

well the diff swap is going to pay off, literally.

I got an average of 25.5mpg with the car full to the brim of stuff and passengers for a camping trip.
I will have to calculate the 'ideal conditions' efficiency (only driver + no extra weight + feather foot) but i suspect it to be 28-29mpg.

I put about 10,000 miles on annually, so the increase from 20 to 25.5 mpg with save me about $500 or so per year.

8)
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Re: Dan's 2nd E30 Build

Postby boy412 » Sun Dec 08, 2013 3:17 pm

I registered here just so I could post in this thread! I like what you've done with the car. The DS1's look great even though the adapters sound like they were a PITA to get right. I had Motorsport Tech make some adapters for my Audi and am pretty happy with them. Sorry to hear your experience was not a good one.

Also enjoying your lighting mods! I'd love to have HID's on my E30. Would also love the crosshairs but don't want smoked housings. Nice work!

I'm currently running a 3.73 LSD on my car and have been thinking of swapping it out for something else. Just needs longer legs for highway cruising! The ratio you chose seems just about right. I'll have to start looking for one, or see if someone wants to trade.
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