E34 540i/6 Turbo Build - The game is on.

[danieljames]

Dude.......

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[danieljames]

Love it, stock engine yeah?
Gonna build a forged engine with o rings so you can run 2 bar?

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[DUDMD]

Love it, stock engine yeah?
Gonna build a forged engine with o rings so you can run 2 bar?

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Nahh, going to keep it stock. Shooting for 10lbs of boost on pump, and maybe 1bar (15psi) on some MS109.
While it would be nice to go with forged pistons, the stock sleeves will need to be replaced to run anything aftermarket.

[danieljames]

Nahh, going to keep it stock. Shooting for 10lbs of boost on pump, and maybe 1bar (15psi) on some MS109.
While it would be nice to go with forged pistons, the stock sleeves will need to be replaced to run anything aftermarket.

Sleeves? Thought these Alusil blocks were new castings after the debacle with the silicone content.......

May as well start building one dud....... You know where the boost addiction leads!!!!
I have some leads on some awesome stainless valves and double behive springs. Not to mention valve stems and piston design. We could have an old m60 4.0 holding 800hp plus!!! All from a friend who built the 1000hp Nissan gtp engines back in the 80's.......

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[DUDMD]

I'd rather keep the power down and enjoy it at 500-600hp at the crank. While more power would be nice, it wouldn't be really useable on the street.

[danieljames]

I'd rather keep the power down and enjoy it at 500-600hp at the crank. While more power would be nice, it wouldn't be really useable on the street.

With your diagnostics/monitoring will it be possible to shut it down before meltdown or do these engines go, go, go then BLOW. Awesome turn around by the way. All that talk about your tune keeping sales up so you can do more of this!?!?

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[DUDMD]

With your diagnostics/monitoring will it be possible to shut it down before meltdown or do these engines go, go, go then BLOW. Awesome turn around by the way. All that talk about your tune keeping sales up so you can do more of this!?!?

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Hard to say. I think the limits right now are the stock headgaskets and head bolts. After that, the pistons.

[staystackin]

Great work. Exciting stuff going on here.

[UnrulyGrace]

So much want...

[516SC]

Did You open the old engine?

[DUDMD]

Did You open the old engine?

I didn't, I just gave it away pretty much to another member on here. He'll be taking it apart, I'll ask him for a picture.

- - - Updated - - -

Figured out why I couldn't adjust the idle at all, turns out the ICV was stuck in nearly closed position the entire time.
Plugged in a spare and I could actually see it open/close to new positions with different duty cycles.
After that, the idle control works fine now, just got to tune it in closed loop.
My friend also dropped off some new clamps he made for me to get rid of the t-bolts for the ICV hose. He made 2 different IDs so that in case the larger one is too lose, the smaller ID can tighten the hose properly. Worked perfect, the ICV side used a large one than the barb one on the elbow.

Intake setup is completed and installed.







Drove it for the first time since the turbo setup. Went to the gas station, live data looked good.
Pulled a bit of timing for boost, only running 20 degrees at 5psi. Fuel looked good. Set the rpm limiter to 5500 and got on it a few times.
Felt great and pulled good for just 5psi and low limiter.

Now just awaiting for the new crankcase setup and back on the dyno she goes.

[GazM3]

Nice.

A fireworks show at the end as well.

[danieljames]

Beast mode! I can't tell you how many times I've watched your YouTube video. Love it.

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[BenzoNI]

Any word on mapping or power runs? Sounds great in those photos, bet it's great fun!

[E38740iMD]

awaiting dyno results and video

[dangerwillrbnsn]

"Fuck. Shit. Jesus...

Fuck shit Jesus is right."

[DUDMD]

Might install the new crankcase vent setup today or tomorrow, then it will be ready for the dyno.

[jimmyz66]

Following your example and I also went with a standalone instead of oem ecu tuning. Good luck with your final results, I am sure they will be awesome.

[QuiqueUY]

Wow , that is great ! haha can't wait for the dyno!

Great job!

[93FIM5]

Might install the new crankcase vent setup today or tomorrow, then it will be ready for the dyno.

[BenzoNI]

Might install the new crankcase vent setup today or tomorrow, then it will be ready for the dyno.

How does the new setup work? What have you planned.

A lot of the swedes have just blanked the Inlet manifold and welded AN10/12 fittings to the back of the Rockers and the PCV Blank plate and piped them into a catch can.

That Seems to be the norm.

[DUDMD]

Got the ProVent200 installed, thanks to 93FIM5
Modified the provent bracket a bit, relocated the power steering pump reservoir and shortened PS hoses. Ran the 3/4" intlet, into a 3/4" to 1" silicone adapter elbow.
Then a 1" elbow into 1" vibrant hose into the intake.
The silicone adapter elbows, and the aluminum hose joiners were bought from Pegasus, really nice quality parts.
The bottom of the provent has a hose leading to a sealed catch can under drivers headlight.
Got the car on the dyno, and the vent setup worked really well. The oil filled up the can really quick, while nothing went into the intake. But that also means I need to change the source of the crankcase to vent. So I'll be sealing the current source and going to the top of the drivers valve cover to get a cleaner crankcase source with less oil.

[DUDMD]

And then onto the dyno.
It made 316WHP at 6psi, and 386WHP 391WTQ at 9.5-10psi, very conservative timing. AFR at around 11.5 to be on the safe end of pump 92.
Need to remember that this is a very low reading dyno dynamics. 386WHP here is around 430WHP on a dynojet, and 500HP crank.
I would need to install some higher psi springs if I want to raise the boost any higher on pump. On race I can set it a little higher before maxing out the boost solenoid on current 5psi springs and throw some timing at it, should be possible to hit 450whp current setup with good fuel.
Currently at 76% duty cycle of the boost solenoid to hit 10psi on 5psi springs. I will keep it like this for now, and see if boost by gear is needed with my drag radials in 1st and 2nd, if it holds all 10psi down low, then I can throw some 10psi springs and turn up the boost later on once all the little bugs are worked out.
Injector duty cycle is only at 40%, so tons of room there.

[staystackin]

Very awesome. You figure you've gained 100hp then? a bit more than 100 tq?

I didn't read back for initial readings or if you did a baseline dyno on the same dyno. my apologies

[DUDMD]

Very awesome. You figure you've gained 100hp then? a bit more than 100 tq?

I didn't read back for initial readings or if you did a baseline dyno on the same dyno. my apologies

I haven't dynod an M60 on this dyno yet, but a M62B44TU 6 speed makes 218WHP here. M60 I figure will be very close, so about a 150-160WHP gains on this dyno. 386WHP on this dyno is at 500hp crank.