Category: Maxxd News

  • MODIFIED BMW 2002: OLD-SCHOOL RULES

    Effortlessly blending classic looks, Group 2-inspired styling, perfect stance and the small matter of a 2.5 S14 swap from an E30 M3, this full-on modified BMW 2002 is nothing short of a masterpiece.

    Feature from Performance BMW. Words: Elizabeth de Latour. Photos: Mike Crawat.

    If you’re talking about BMW legends, icons, then the ’02 family absolutely has to be on that list. It’s an incredibly important part of BMW’s history and whether you’re talking about the original 1600-02 or something like the 2002 tii, it’s a much-loved range that remains popular with both BMW aficionados and modding enthusiasts. And speaking of which, there have been some magnificent builds that we’ve come across over the years, but Georg Schuster’s (@the_bavarian_outlaw) magnificent creation is one of the best.

    Regular readers might find Georg’s name familiar and that’s because we had the pleasure of featuring one of his other creations, an epic S38-powered Group 5 E9 replica, in our April 2020 issue. That alone made it clear that this proud Bavarian is a huge petrolhead but this ’02 is even more of a special machine and no component has been left untouched during the extensive journey of its build. As a brief recap, Georg is a car mechanic and he co-owns a petrol station with his dad so every part of his life revolves around cars and, being a born and bred Bavarian, you’d be very surprised if he wasn’t passionate about BMWs. But he’s also passionate about cars in general – his first was a Porsche 928 GTS, which is an amazing way to kick off your motoring career, and his passion for all things automotive is reflected in his current collection, which includes a Mk1 Ford Escort RS2000, a Chevrolet pickup and an Audi 8L S3 alongside his BMW duo. George says that spending time in his garage is his favourite hobby and we have no doubts about that.

    Modified BMW 2002

    The ’02, though, might just be the most important car for several reasons, the main one being that this was his first-ever BMW. George is 36 now and this car, which started out life as a 1502, was purchased when he was 18 back in 2002 (funnily enough). The entire project was undertaken over two years, which means this isn’t a recent creation, but, unsurprisingly, he’s kept the car for 18 years because a build on this scale is not something you’re ever likely to sell.

    The ’02 itself was actually instrumental in igniting Georg’s passion for BMWs in the first place – when he was around 16 or 17 his dad told him that you could swap an E30 M3 engine into a 2002, which intrigued him and got him hooked and that’s exactly why this project came about. “We went to the BMW Group Classic (museum) and I saw the 2002 with the Group 2 body kit – it was just in red, but with these same wheels – and that is when I fell in love with that particular model,” he smiles and it served as the inspiration for this whole build.

    Step one was to locate a suitable ’02 for the project and here lady luck, fate and the BMW gods all joined forces to give Georg and his dad, with whom he has built all of his projects, a helping hand. “We were lucky!” he grins, “We found this 2002 by chance, one where the motor I wanted (the S14 from an E30 M3) was already fitted. The car was situated in Bochum, Germany; it’s about a six-hour drive which my father and I did together. Since the car was a project it was in bits upon purchase so we took a Mercedes Sprinter and a trailer to pick it up. There’s a funny story to that, actually: the car was initially on eBay as an auction as the guy had started his project and couldn’t be bothered to continue with it. We called the seller regardless of the auction and negotiated the price over the phone; of course, we checked the condition etc. beforehand and, looking back, it might have been bold but it all worked out. We agreed on a price of €10,000 and he removed it from the auction on eBay,” he says and that sounds like an absolute bargain for a 2002 with an S14 already swapped in. Seeing as that was to be a major part of the project, finding a car for sale with the engine already taken care of was a major win. This was the perfect jumping-off point for the build and, over the next two years, the unfinished 2002 was totally transformed, with Georg and his dad bringing their perfect vision to life.

    “Since the car was already stripped, with the (original) body removed and the motor was in place, it made sense for us to work on the motor first. We ordered the body kit thereafter and while waiting made our way through the chassis and engine modifications,” explains Georg and the work undertaken at every stage of this build has never been anything less than incredibly extensive. The S14 needs no introduction and fitting one into an ’02, to create what the community likes to call an M2, results in a seriously potent little machine, but just running a stock S14 would not have sufficed for Georg and his dad and so this one has been treated to a selection of substantial upgrades.

    Modified BMW 2002

    First of all, this is not just a regular S14, this is the 2.5-litre unit from an M3 Sport Evo and beneath the surface, you will find a lighter DTM crankshaft, H-beam Pauter con rods, one-off Wössner pistons, BMW Motorsport DTM cams, a machined head with ported and polished intake and exhaust ports, increased compression, E34 M5 valves, Audi R8 coil packs, a custom larger sump, electric water pump and an MBE ECU to oversee everything. The engine’s crowning glory and what immediately gets all the attention when the bonnet is raised is that absolutely awesome original DTM carbon airbox and intake manifold, and a quick glance at Georg’s Insta videos confirms that it sounds every bit as good as it looks. The result of those seriously extensive mods is an extremely impressive 306hp, a hell of a lot of power in a car as small and light as the 2002, and that makes it insanely exciting to drive. The car runs an E30 M3 gearbox, which required the transmission tunnel to be enlarged for it to be able to fit, and there’s a 45% locking LSD at the rear. The whole package is just superb and the S14 looks like it was made for the ’02’s engine bay, fitting perfectly, and Georg has also gone the extra mile to make sure that presentation is on point by tidying up the engine bay, thus allowing you to enjoy that legendary four-pot in all its glory and it does look magnificent.

    With the engine work taken care of, Georg and his dad now moved onto the next major part of the project, the bodywork. As the inspiration for the project was the Group 2 2002 that they had seen at BMW Group Classic, the plan was to create a road-going car with that awesome wide-arch Group 2 styling and so the next step was to order the body kit, which consists of that ultra-aggressive front bumper and the bolt-on arches. “It wasn’t all that easy to get the parts fitted in place as there were no pre-drilled holes to fit the body in place. Let’s just say, it paid for me to be a fully trained mechanic,” grins Georg and his talent and skills paid off in a big way as the end result is spectacular and while the kit may only be made up of the front bumper and arches, the visual drama they impart on the 2002’s body is insane. The front bumper is wide and wild, angular and aggressive with that central ‘V’ section, those air intakes and the lower splitter section, and it aligns with the front arches, which sweep up and over and then tuck down into the sills and not only do they endow the 2002 with an almost cartoonish muscularity, the bolts and the black gaskets add an element of contrast and give them even more definition. At the rear, meanwhile, Georg has removed the bumper and cleaned up the area to leave the ’02’s rump looking super smooth, with that exceedingly cool oval exhaust tip from the custom manifold-back exhaust system adding the finishing touch. With the Group 2 elements in place, the body needed a fresh coat of paint and while you might not think silver is an especially exciting choice of colour, this isn’t just any silver, oh no, this is Mercedes Brilliant Silver metallic, which Georg says gives a hint of golden glow in full sun, adding yet another element to the visual aspect of this build.

    Modified BMW 2002

    Of course, just adding wide arches to a 2002 would be a half-hearted job and that’s not how Georg and his dad do things. First off, the ’02 needed lowering, and it’s been fitted with Bilstein coilovers all-round with the rear having received some significant upgrades in the form of an E21 323i rear axle with welded strut domes and the setup has been modified for MacPherson struts with springs welded in. The drop that the suspension setup delivers is perfect and gets the car sitting low, with the arches perfectly placed over the wheels, and of course, the wheels count for so much here, because a) wide arches require some equally wide wheels to fill them out properly and b) sticking to the Group 2 vision meant that there was only one set that would suffice for Georg. “These are the wheels on the 2002 Group 2 racing car in the BMW Group Classic museum and it was those I wanted, I never considered any others,” he grins and while finding a set of BBS E50 magnesium splits couldn’t have been easy it was absolutely worth the effort as they make this build. These stout 17s measure 9.5”-wide up front and a hefty 11” at the rear, ensuring those arches are suitably stuffed, and the combo of those gold centres and polished stepped lips is a stunning one. The tight cross-spoke pattern makes it hard to see, but the BBSs are mounted over Porsche 993 911 Turbo 330mm discs with four-pot calipers up front while at the rear there are E21 323i single-piston calipers and 258mm discs, and this ensures he’s got more than enough braking power on tap when trying to tame 306hp.

    Finally, we come to the interior, and it’s no less spectacular than any other part of this build and an insane amount of work has gone into this ’02’s cabin. The first thing you will notice are those magnificent Porsche 993 911 GT2 seats, which look absolutely awesome and are equipped with silver Schroth harnesses. Then you’ve got that Stack digital racing display custom-mounted with a carbon surround and there’s also a custom centre console with a carbon panel. The headlining, rear bench and dashboard have all been completely retrimmed in either Porsche blue leather or blue Alcantara and it makes the interior look so upmarket and feel so special. The steering wheel is a dished Momo item with an Alcantara rim and a BMW centre badge and there’s also a BMW M gear knob with an Audi TT surround and it all combines to create an insanely nice cabin that just looks awesome.

    When we say that Georg and his dad spent two years working on this car we really mean that – Georg says that they basically worked on the car almost continuously for that period, only taking breaks for holidays like Christmas and New year, and that’s an incredibly impressive commitment to the project, but hard work pays off and the result is something truly exceptional. The fact that this was Georg’s first BMW, that it was inspired by a Group 2 2002, that he and his dad stayed so close and true to their vision for the build and the fact that, 18 years on, the 2002 is still a part of his car collection, still a part of his family, is something truly special. “All the modifications that we did were carried out with the original use in mind, for this to be a racing car as you’d find it in the museum but fully legal and on the road. My preferred style is racing technology for the road and my aim is always to get to the limit of what the TÜV test in Germany will allow. I’ve done that with all the cars I still own, no exceptions,” grins Georg and this modified BMW 2002 is proof of that. It looks awesome, it sounds awesome and we can only imagine how much fun it is to drive. This 2002 is the result of what you can achieve when you follow your dreams, it’s inspirational, beautifully built and, above all else, an absolutely awesome road legal, race car-inspired machine and it’s a project that Georg and his dad can be truly proud of.

    Modified BMW 2002

    Tech Spec: Modified BMW 2002

    Engine & Transmission:

    2.5-litre four-cylinder S14B25 from E30 M3 Sport Evo, lighter DTM crankshaft, H-beam Pauter connecting rods, one-off Wössner pistons, BMW Motorsport DTM camshafts, mechanical bucket tappets, machined cylinder head, enlarged and polished intake and exhaust ports, increased compression ratio, E34 M5 valves, genuine DTM carbon air box and intake manifold, Audi R8 ignition coils, custom-made enlarged sump, electronic water pump, E30 M3 exhaust manifold, homemade manifold-back exhaust system, MBE ECU, engine bay tidied. Getrag 265 five-speed manual gearbox from E30 M3, enlarged transmission tunnel, 45% locking LSD

    Chassis:

    9.5×17” (front) and 11×17” (rear) BBS E50 magnesium wheels with gold centres and polished stepped lips, 225/35 (front) and 255/45 (rear) Yokohama Advan Fleva tyres, Bilstein coilovers, E21 323i rear axle and welded suspension turrets, modified to MacPherson suspension struts, springs welded in, Porsche 993 911 Turbo four-piston calipers and 330mm discs (front) and E21 323i single-piston calipers and 258mm drilled discs (rear)

    Exterior:

    Full respray in Mercedes Brilliant Silver metallic, Group 2-look GRP front bumper and wide arches, rear bumper delete

    Interior:

    Porsche 993 911 GT2 seats, silver Schroth harnesses, interior retrimmed in Porsche blue leather and blue Alcantara, custom-mounted Stack digital race display with carbon fibre surround, custom carbon fibre centre console, Momo Motorsport steering wheel with BMW centre badge, BMW M gear knob, Audi TT gear shift surround

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  • HOW TO PREPARE YOUR CAR FOR A TRACK DAY

    Race circuits are the perfect place to push your driving skills to the max, but you must ensure your car is ready for the stress. Following this simple guide on how to prepare your car for a track day before you go will enhance your enjoyment and take a lot of the fear out of it. It should also help you bring your pride and joy home in one piece!

    Prepare your car for a track day

    Assuming your car is in good general condition (a recent service is advantageous), here are the most important things to check.

    Prepare your car for a track day

    Fluids

    Ensure that your oil and coolant are up to their maximum marks – take extra with you so you can top up during the day if required. High cornering speeds on track make the oil in your sump move around much more than on the road and can force it away from your oil pump pick-up, which can lead to oil starvation and engine failure – which is why most race cars have baffled sumps – however, this situation is also much more likely if you have low oil levels, so make sure your properly lubed up. Also, your coolant will be working overtime to keep a caned engine cool, so keep an eye on it throughout the day if you want to avoid a cooked engine and blown headgasket. Coolant additives such as Water Wetter or waterless coolants such as Evans Powercool 180 can help keep temps down too.

    Brakes

    Your brakes will be put under much greater pressure on a trackday, as you brake hard and regularly from high speeds, increasing brake temperatures and wear. A larger multi-piston set up is ideal, but with careful monitoring of their condition, normal road brakes should be fine. Ideally, it’s best to have at least three-quarters of your pad material remaining before any trackday. Running with destroyed pads will dramatically reduce your stopping capacity and quickly kill your discs. It could be worth looking at uprated pads before the day, but remember to bed them in before doing any heavy braking on track. Brake fluid is also important, as higher temperatures increase the risk of boiling the fluid. A good tip is to make sure the brake fluid you have is reasonably fresh. You can check out our guide on high performance brakes here.

    Wheels and Tyres

    Having a dedicated set of lightweight trackday wheels and sticky tyres – such as slicks or semi-slicks – is a nicety, but not a necessity. Normal road wheels and tyres will be fine in most cases, but just make sure the rubber has plenty of tread (you’ll have to drive home afterwards, remember) and that pressures are at the recommended levels. It’s also worth giving your wheel nuts a good torquing too, as you don’t want to be departing with your rims down the main straight!

    Bodywork

    Check that there is no loose bodywork and ideally that the headlights are taped-up. This way, if the worst happens and you lose a light, broken plastic or glass won’t be scattered over the circuit to cause punctures for following vehicles. Some people will remove one of the headlights completely, which helps gain additional airflow to the air filter behind. Splitters, spoilers and skirts can aid track driving, but won’t generate any usable downforce, merely modify the car’s pitch and reduce lift. Swapping heavy steel body panels for lightweight carbon items will improve your car’s performance – due to a higher power-to-weight ratio – but make sure you retain the front-to-rear weight balance. Our guide to car aerodynamics offers more advice on improving your car’s performance, you can read it here.

    Prepare your car for a track day

    Interior

    Inside, remove anything loose in the door pockets and footwells that could become a missile under heavy braking or acceleration, or worse, get jammed under a pedal.

    For the more serious trackday fiend, a bucket seat with harnesses is a good move, as is removing extra weight like the rear seats, passenger seat and excess plastic trim. Rollcages are a good option if you are a trackday regular and are concerned about safety in the event of a crash, but are generally not compulsory unless you are competing in a regulated series. Video cameras need to be securely mounted without causing an obstruction and most trackday organisers will want you to sign a disclaimer that states the footage is for private use only. Those who want to lose a bit more weight inside can check out our top 10 ways to make your car lighter guide.

    What track day should I pick?

    With loads of events each month all over the country (Covid permitting) finding a trackday to suit won’t be an issue, but here are a few things to consider before booking:

    Noise limits: This is set by the local council and will be strictly enforced. If you’ve got a loud aftermarket exhaust, get the dB levels checked. If your car is too loud, you won’t be allowed on track.

    Format: You have two main choices: ‘session’ or ‘open pitlane’. The former groups drivers of similar ability into 20-30 minute sessions – this is probably the best bet for newbies. Open pitlane days offer as little or as much track time as you want (as long as the maximum number of cars on track isn’t exceeded), but usually cost more, as numbers have to be restricted by the organiser.

    Instruction: Check if there is an ARDS (Association of Race driving Schools) instructor on hand. You’ll find a 20-minute session (about £50), with your own personal Stig, will teach you loads and boost your confidence.

    Prepare your car for a track day

    What to expect on a track day

    At the track you’ll get a short briefing that covers the format and rules for the day and the flag signals. The main rules cover how and when you can overtake and that you must NOT race! Track marshals positioned around the circuit monitor this closely and anyone breaking this important rule will be immediately pulled in to explain themselves. On your first few laps, you probably won’t be familiar with the track and your tyres will be cold. Do not be tempted to go for it straight away as this is probably the time you are mostly likely to have an off! Start slow and build up speed as your confidence grows and tyres warm up. Throwing the car around might be fun, but if you overdo it, you may unsettle the car and risk going off (plus it will take its toll on the car with parts wearing out faster!). Concentrate on driving smoothly – smooth is fast. Aim for getting braking points and corner apexes right. Get your gear changes and braking done in a straight line before turning into a corner then feed the power in gently as you exit the corner and don’t forget to wind the steering lock off as you exit. Practice keeping steering inputs to a minimum.

    After a session, always complete a cool-down lap to get some air to the brakes, engine and the transmission, and once stopped in the pits DON’T apply the handbrake, as the pads can fuse themselves to the discs if you’ve been using them hard. Popping the bonnet will help cool the engine too, which gives you a chance to double-check your fluid levels. Also, check the tyres again for excessive wear and that the pressures are still OK; and that all the wheelnuts are tight.

    First appeared in Fast Car magazine.

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  • CONCOURS FORD SIERRA RS500 COSWORTH: BLACK MIRROR

    With 450bhp on tap, this Concours Ford Sierra RS500 Cosworth is a very dark (and shiny!) horse that’s taken home a title.

    Feature from Fast Ford. Words Ben Birch. Photos Jason Dodd

    Few Fords look more menacing in your rear-view mirror than a black Ford Sierra RS500 Cosworth. In the 1980s, whether you drove a Porsche 911 on the street or a BMW touring car on the track, Ford’s ultimate Sierra left a terrifying impression on anyone it pushed out of the way.

    Kev Murby’s experience of the whale-tailed icon was slightly less visceral, but no less memorable. “I had a very unique picture on my wall at work; it was of a black Ford Sierra RS500 Cosworth parked in front of a futuristic-looking glass building. Every single day I looked at that picture, and promised myself that I’d own one,” he remembers.

    Fast forward a few decades and Kev has fulfilled that promise while at the same time bringing this particular example back to its former glory. As he explains, “I came into some money around 2014, and wanted to finally scratch my RS500 itch, but prices were on the increase already and there was no way I could justify spending £100,000 on what is still a Ford Sierra.”

    Concours Ford Sierra RS500 Cosworth

    Kev was determined to buy a solid car but not a minter, at a sensible price. Oh, and it had to be black. He says, “Over the years, I’ve owned a black Mk3 Cortina, a black XR4i, a black JPS Capri, and I’ve got a black rear-wheel-drive Sapphire Cosworth at home, as well as the RS500. Black cars just look better than any other colour – when they’re clean,
    of course.”

    Most of us would have failed in finding such a unicorn, but after years of competing in concours events with his Saph, Kev was well connected on the RS scene. He received a friendly tip-off about a Sierra RS500 from well-known Cosworth aficionado Paul Linfoot.

    Kev explains, “I think Paul wanted to keep it for himself, but he was in the process of buying a very special RS500 at the time, so sold this one to me to free up some cash.”

    Although the car was tired and had been badly painted, it was very straight and honest, and all the important numbers matched – including the engine block and head. At £30,000 it was also good value, so without having even viewed the car, Kev organised for it to be picked up and delivered to his home, where the rebirth of an icon could begin.

    Kev didn’t hang about: within a week the engine was out of the bay to be assessed by Dave Pritchard of DP Motorsport, and the car was up on axle stands, where a long and arduous love-hate relationship began between the garage floor and Kev’s back.

    He groans, “I spent around three hours every night for months on end, laid down, looking up at the floorpan, cleaning the underside with my little Dremel. It was horrific work and I wouldn’t do it again for all the tea in China, but once the red oxide and paint was on, the result was worth it.”

    Concours Ford Sierra RS500 Cosworth

    By now, Dave Pritchard had dismantled the engine and discovered some good and some bad news. The good news was some trick head work had been done back in the day, by Dave Brodie of BBR. Kev says, “It was superb work, but unfortunately the rest of the engine needed a rebuild, as internally it looked like it had been sandblasted.”

    The discovery offered Kev the impetus to rebuild it to better-than-new condition. “DP asked what I wanted from the rebuild, and I said to be driveable and quick. We ended up making 447bhp and 396lb.ft, and although you need to stay above 4000rpm to really keep it on song, it is very quick indeed.”

    The concours Ford Sierra RS500 Cosworth runs four big Siemens injectors, and the T4 turbo has been rebuilt with billet wheels because the originals are hard to get hold of nowadays. The whole ensemble is kept in tune with a retrofitted Level 8 ECU, live-mapped by PJ Motorsport to a maximum 28psi of boost. Kev doesn’t see a need to go any further, and he sums up the experience of a 400bhp-plus T4-equipped rear-wheel-drive Cosworth road car perfectly: “Hit the right revs, and all hell breaks loose.”

    The engine went back into an already-mint bay, as Paul Linfoot had previously conducted one of his underbonnet restorations. The rest of the bodywork desperately needed attention, but an initial respray ended in tears.

    Kev explains, “I’d wanted Wayne Parrott to do it, but he was busy with work. So I took it somewhere else, and a year later, the whole car micro-blistered.” In fact, when Wayne assessed the damage, he was able to peel the paint off in strips with a razor blade.

    Kev was wounded, but after a second respray, by Wayne this time, the car is still in stunning condition five years later. So much so that Kev has enjoyed entering it into concours competitions alongside his Saph.

    Concours Ford Sierra RS500 Cosworth

    He says, “My son and I drive the cars to the events, show the cars and then have some great drives home. They do get used hard, which surprises some people, but life’s too short not to enjoy these cars properly.”

    Kev swaps the CXN wheels for a standard set of genuine RS500 items to enter concours, and with such a relatively standard-looking car he has won his fair share of events.

    He smiles, “My proudest moment was winning the best-presented standard car at RSOC National Day. It genuinely bought a tear to my eye with pride.

    Concours Ford Sierra RS500 Cosworth

    “The RS500 ownership experience is much like owning other Cosworths. I get immense pleasure out of driving it, and the cars deserve to be brought to the best condition they can – striving for that goal can also bring their owners so much pleasure.”

    So much that Kev has now become the RSOC RS500 registrar. Does that mean he can officially value his own car? “Unfortunately not. But even if I could, it’s not about the monetary value – I’ve finally got the car from that poster, and that’s priceless.”

    Tech Spec: Concours Ford Sierra RS500 Cosworth

    Engine:

    BBR polished and ported head with larger valve guides, DP Motorsport exhaust cam, Isky double valve springs, Mahle pistons with valve cutouts, H-section conrods, high-pressure oil pump, -31 actuator, 3 bar MAP sensor, four Siemens black 83lb injectors, T4 turbo with billet wheel

    Power:

    447bhp and 396lb.ft

    Transmission:

    T5 gearbox with toughened gears, competition clutch and flywheel

    Suspension:

    Standard springs, Koni adjustable dampers, partially poly bushed

    Brakes:

    Standard callipers, drilled discs

    Wheels & Tyres:

    Front: 9x17in Compomotive CXN wheels and 215/40R17 Toyo tyres; rear: 9x17in Compomotive CXN wheels and 235/40R17 Toyo tyres

    Exterior:

    Original Sierra Cosworth RS500 in black

    Interior:

    Original Sierra Cosworth RS500

    Source