E34 540i/6 Turbo Build

[5mall5nail5]

It's actually not "machined out of plastic" it's plastic printed off in thin molten strands to build up the item

Minor detail though.

[DUDMD]

It's actually not "machined out of plastic" it's plastic printed off in thin molten strands to build up the item

Minor detail though.

Thanks for clarifying. I didn't know if he printed that or not.

[93FIM5]

Glad to see it fits! I'll PM you tomorrow and will keep moving on machining them.

Jon is right it was 3D printed not machined, Im too lazy to machine prototypes now lol.

[e34biturbo]

Greg,
The prototype showed up this morning. The first thing I did was go in the garage and test fit.

The piece fit perfect. Every bolt hole lines up nicely and the plate overall fits perfect.
Thanks again for doing this. I don't think anything needs to be changed from the prototype.

Sorry for the iphone pictures:

That Is as choice!!looks great

[ZenitramNaes]

Can't beleive I haven't seen this thread till just now. Looking nice! Very interesting way to do things!

[NelsonAviles]

Any updates? Im starting a e39 540i turbo project soon,need to buy one of those intake rear covers.Who sells them?

[nsogiba]

Any updates? Im starting a e39 540i turbo project soon,need to buy one of those intake rear covers.Who sells them?

I have one or two of those rear covers for M60/M62 application. Pulled them off wrecked cars. Looks like you can't PM yet, so shoot me an email at nogiba5@gmail.com !

[Zedbimmer]

Looking at the limited space wouldn't it have been easier to go twin turbo using mitsubishi 20g type small turboes that pack a punch dual?

[oziee]

Hi ppl i have a e90 320d 2005
Recently i replaced my turbo because my turbo was gone . Got my car back yesterday unfurtuantly im not happy at all . The problem is my car slowed down and picks up the speed to late . Enginier said that his gona have a look at it tomorrow . Do you guys have any idea what why is this happening

[imae30driver]

Hi ppl i have a e90 320d 2005
Recently i replaced my turbo because my turbo was gone . Got my car back yesterday unfurtuantly im not happy at all . The problem is my car slowed down and picks up the speed to late . Enginier said that his gona have a look at it tomorrow . Do you guys have any idea what why is this happening

If you jack this guys build thread, I Kill You!

how is it comming???!!!

I have a thread for best e34s period at bimmerfest.com im nominating you..

[BigM62]

If you jack this guys build thread, I Kill You!

how is it comming???!!!

I have a thread for best e34s period at beemerfest.com im nominating you..

Then you have not seen my car.

[imae30driver]

Is there any updates on this build?

[Matt Z]

Update???

[98 528i]

Subscribed

[Def]

BTW - I know I'm about a year late, but I just saw the FDM 3D printed PCV cover. One caution - all FDM stuff leaks air, quite a bit of it actually, due to the manufacturing method (molten strands extruded on top of each other, think squeezing out toothpaste in a line, but it's melted plastic).

There are a few ways to seal it, the best being either superglue or a low viscosity version of Loctite Hysol. It's recommended you pull a vacuum on the other side, but I think for our purposes a thin layer will do the trick.

Also, don't be afraid to throw some stiffening ribs on a large plate like that, it's FDM, it can make almost any shape you design.

[tptrsn]

I thought the FDM part was just for the purposes of checking the design and then the actual parts were to be CNC'd from aluminum?

[98 528i]

I thought the FDM part was just for the purposes of checking the design and then the actual parts were to be CNC'd from aluminum?

That's what got too from what I read.

[Rebel635csi]

There's another trick to seal 3D printed ABS. Acetone bath. Its what i use when i need a smooth or sealed 3d model.

Suspend the object in a large metal or glass container and pour a bit of acetone at the bottom. Heat up on a boiler plate or oven and it will create an acetone vapor that will melt the ABS together. Dont leave it in too long or get it too hot as it will start to totally dissolve the part.

http://www.dvice.com/2013-3-3/duo-sm...ousehold-items

BTW - I know I'm about a year late, but I just saw the FDM 3D printed PCV cover. One caution - all FDM stuff leaks air, quite a bit of it actually, due to the manufacturing method (molten strands extruded on top of each other, think squeezing out toothpaste in a line, but it's melted plastic).

There are a few ways to seal it, the best being either superglue or a low viscosity version of Loctite Hysol. It's recommended you pull a vacuum on the other side, but I think for our purposes a thin layer will do the trick.

Also, don't be afraid to throw some stiffening ribs on a large plate like that, it's FDM, it can make almost any shape you design.

[93FIM5]

BTW - I know I'm about a year late, but I just saw the FDM 3D printed PCV cover. One caution - all FDM stuff leaks air, quite a bit of it actually, due to the manufacturing method (molten strands extruded on top of each other, think squeezing out toothpaste in a line, but it's melted plastic).

There are a few ways to seal it, the best being either superglue or a low viscosity version of Loctite Hysol. It's recommended you pull a vacuum on the other side, but I think for our purposes a thin layer will do the trick.

Also, don't be afraid to throw some stiffening ribs on a large plate like that, it's FDM, it can make almost any shape you design.

The FDM part was just for test fitment, the final part was CNC machined and hard anodized.



Yup lots of ways to seal FDM parts depending on the end use, we tend to do mainly vacuum infusion with a low viscosity resin. Also do vapor smoothing for parts that require it.

-Greg

[Def]

Gotcha, missed that the first time.

[imae30driver]

Update please! Love the tune fyi DUDMD...

hoping to run 101 octain and nitrous with it (@my own risk lol)

[arturb]

updates?

[swanni]

Updates please just subscribe, I'm interested in doing a turbo set up my 540 6sp

[DUDMD]

Soon, might end up changing up a few things for this build.
I'm hoping to resume work on this project soon.

[jimmyz66]

Soon, might end up changing up a few things for this build.
I'm hoping to resume work on this project soon.

Thanks for update. And hope you plan to duplicate this project.