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

[DUDMD]

I'll be the 8th soon.

Congratulations on starting this. I actually started collecting parts only yesterday. I'm going to go bottom mount using 2 WRX turbos. Not aiming for your hp goal. :P

Please, PLEASE take tons of pics. Also, why are you installing the intercooler behind the radiator? If you removed everything A/C related like I have, there's ample space in front of the radiator (behind the kidneys). Also, what injectors are you going to use? That's something I'm still looking into. Wouldn't S62 injectors work?

Intercooler going in front of the radiator.
Injectors are Delphi 75lb (around 800cc), pretty much any injector that is a mustang fitment will work. S62 injectors won't flow enough fuel for my power goal.
I would reconsider doing twin turbo because there is simply no space on the drivers side for the turbo. I'll be lucky to run the crossover manifold under the motor, if not then I'll have to back around the tranny and come up front again on the passenger side.

Are you planning on running uneven length headers? Any idea on how you will be running the driver's side bank to the turbo?

They will be uneven, but that is no a problem at all on a turbo car. I'm hoping to build a 4-1 manifold on the drivers side and run it down by the steering link to crossover if I have enough space. If not enough clearance then probably back around the bell housing.

I'll have to wait until I'm back with the car to see what color they are... I can't remember. They're 42#'ers. No modification required.

42lbers are green.

this is going to be badass.

got any links to those other turbo M60s thta you mention?

[ame]http://www.youtube.com/watch?v=3btEVk2n8_o[/ame]

This guy has a few vids up:
[ame]http://www.youtube.com/watch?v=gBc1CjOvmNo[/ame]

E28 M60:
http://server.pure-pf.com/phpBB/viewtopic.php?t=57827

E34 540i/6, small turbo but makes good torque and power still:
http://forums.bimmerforums.com/forum...ght=turbo+540i

Then there's the dinan race car, which I don't have a link to the PDF right now.

And this guy:
http://www.powerfanatics.com/forum/v...r=desc&start=0

[Shoomakan]

Then there's the dinan race car, which I don't have a link to the PDF right now.

http://www.kindel.com/bmw/fast_fives.pdf

Here ya go. 650bhp on a stock internals engine.

[janders211]

Pretty excited about this build

42lbers are green.

There are multiple versions out there. I have them in black, blue, yellow, and green on ebay...not sure if those colors are manufacturer specific.

[DUDMD]

Pretty excited about this build

There are multiple versions out there. I have them in black, blue, yellow, and green on ebay...not sure if those colors are manufacturer specific.

Most of the 42# ones that I have seen were green. I was thinking of getting these injectors, but then I would be almost maxing them out at the power I"m looking to get out of this thing.

[me78569]

Nice I think when we looked at it the cross pipe need to go around the bellhousing, but we didn't measure or anything.

Really excited to see this get done though.

[DUDMD]

7/4/2012 Update:
Ordered an intercooler and BOV, they're on the way.

Removed:
Exhaust
Headers
Alternator
PS Pump
Motor mounts that didn't last, working out the solution with the manufacturer right now.


After laying there under the car for 20 minutes figuring out how I was going to run the crossover, I have decided to run it right next to the subframe and not go back around the bellhousing. Another issue I ran into is that there is virtually no clearance to build even a log manifold with the steering box and other steering components in the way. Instead, I'm going to use the upper half of the headers, and then merge them into one 1.5" SCH10 pipe to clear the steering box crap. Only for the driver's side, the passenger side will get a log manifold to save space.

This is all of my working space on the drivers side, this is after the motor was lifted 2" and pushed over to the passenger side a little.



Not much room to work with or even reach to the headers even after Alternator, Motor Mount, and PS Pump are removed. The crank pulley was missing a bolt, 3 more bolts almost fell out, and the rest were loose too. Whoever changed the water pump years ago did not tighten the bolts.


Passenger side, lot's of room. Will be storing the passenger side manifold, twin gates, crossover pipe and the 3" down pipe all in here.


This is where the manifold's will be cut (driver's side). After cutting them up, they're going back on the motor and I'll fab up a y-joint and start building the crossover pipe from there. Took me about 40-60 minutes to get these suckers out, just because there's is almost no room to get to the nuts.


Plans for today (7/4/2012):
Adjust the steering box since it's really easy to get to now and my steering is really sloppy.
Start building the driver's side manifold.
Order a few parts/supplies.

[kniggit]

Oh australians and your kilowatts.

Saw your thread in the fi section, looking forward to updates!

Mine is finished, well almost, just waiting to put a Brembo BBK and that's it (I really mean it this time!)
look here: http://forums.bimmerforums.com/forum/showthread.php?t=1855067&highlight=purple

The term 'kilowatts' just makes me think of the electric meter on the side of my house, which is neither fast nor cool. Horsepower is a much cooler word.

My American brethren, HP, Miles, Feet, inches etc etc, you do realise that the rest of the world uses the Metric system don't you? It would make life infinitely better if you blokes did too!!!

[DUDMD]

Mine is finished, well almost, just waiting to put a Brembo BBK and that's it (I really mean it this time!)
look here: http://forums.bimmerforums.com/forum/showthread.php?t=1855067&highlight=purple


My American brethren, HP, Miles, Feet, inches etc etc, you do realise that the rest of the world uses the Metric system don't you? It would make life infinitely better if you blokes did too!!!

The rest of the world uses HP, too.

[kniggit]

The rest of the world uses HP, too.

OK, I cede, I will bookmark a KW to HP converter and never mention it again. By the way DUD, I have a spare ESS chip (auto), is it worth anything?

[MissileMech]

Now this peaks the fun o meter!!! The exhaust is gonna be a bitch. I hope you get it worked out.

[Project Taxi]

Would a rack and pinion swap gain some space for a better crossover solution?

Lovin the build so far, keep the updates coming!

[EuroPartConnect]

Whats your timeline on finishing this project?

[camaroguy]

Woot, nice to see this project under way finally! I am definitely going to have to come check out some of the progress along the way.

[DUDMD]

OK, I cede, I will bookmark a KW to HP converter and never mention it again. By the way DUD, I have a spare ESS chip (auto), is it worth anything?

I'm not sure. It's worth as much as someone wants to pay for it.

Would a rack and pinion swap gain some space for a better crossover solution?

Lovin the build so far, keep the updates coming!

It will but, converting to a rack and pinion isn't the easiest thing to do as well. I would rather work around this problem right now then spend more money on converting the steering and possibly still have clearance issues.

Whats your timeline on finishing this project?

Not sure yet, still need to order a few parts, get my motor and tranny mounts replaced. I just work on it on my free time, not in a hurry or a race to finish it.

Woot, nice to see this project under way finally! I am definitely going to have to come check out some of the progress along the way.

Anytime

[Psykick5]

This is gonna be insane!! Subscribed.

[Aradaiel]

Everyone note what ignition coils are being used by the 1000+ hp dragster.

[DUDMD]

Everyone note what ignition coils are being used by the 1000+ hp dragster.

Yeah, stock. Except for they look like obd2 coils.

[Justin6745]

wow, definitely in for the ride!

[DUDMD]

7/5/2012
Things to do:
Working with Revshift to build stronger motor mounts that will surving the punishment (especially the driver's one) and fix the tranny mounts issue (height problem).
Adjust the steering box since it too easy to get to right now, with everything removed on the driver's side.
Start building the driver's side header/manifold.
Possibly go to my friends shop and use his bandsaw to cut off the 5" flange from the exhaust housing.

[sweet e36 pimp]

this is an awesome project.

[DUDMD]

7/5/2012

Working with Revshift to build stronger motor mounts that will survive the punishment (especially the driver's one) and fix the tranny mounts issue (height problem). - EMAILS SENT, Hoping for a quick reply and indestructible mounts this time.
In the meantime, the most ghetto engine mounts ever.


Adjust the steering box since it too easy to get to right now, with everything removed on the driver's side. - DONE, Steering is nice tight when the wheels are straight.

Driver's headers were cut where I wanted them and they're back on the motor. I won't build the crossover section until I get my new motor mounts. The motor is sitting on a couple of 2x4s. Can't do much with the manifold until I get the mounts.
The manifold crossover pipe will be right behind the steering box as pictured here.


The 4-5" (whatever huge) v-band flange is cut off, new 3" v-band will be welded when I'm going to be welding up the manifolds.
OLD - Whatever size that was:


NEW 3" V-band flange:


OLD vs. NEW:

[jimoreno]

Did you looked at installing the passenger side stock exhaust manifolds in the driver's side and see how they looked? Maybe having them pointing forward might be a better option. It has been sometime since I worked on an M60 (I know that the left side is tight as hell!) so I might be wrong.
Also, consider changing the radiator to the full aluminum E36 M3 Mishimoto unit to get rid of all plastic. You will need to source a lower Euro radiator hose for a full bolt on approach (search on this site for the thread). I had it on mine with a split joint lower radiator hose and it didn't gave me any problem up to when that SUV decided to hit my son while making a left turn!

[DUDMD]

Did you looked at installing the passenger side stock exhaust manifolds in the driver's side and see how they looked? Maybe having them pointing forward might be a better option. It has been sometime since I worked on an M60 (I know that the left side is tight as hell!) so I might be wrong.
Also, consider changing the radiator to the full aluminum E36 M3 Mishimoto unit to get rid of all plastic. You will need to source a lower Euro radiator hose for a full bolt on approach (search on this site for the thread). I had it on mine with a split joint lower radiator hose and it didn't gave me any problem up to when that SUV decided to hit my son while making a left turn!

No way the passenger side headers will fit. The driver's side headers barely clear the steering box as it is. One of the passenger headers also has a different bolt pattern.
I'm gonna run the factory radiator, it has never gave me any trouble. If it does go out, then I'll probably get a slightly smaller custom radiator.

[E34nication]

Damn.. 640@ the wheels in that Volvo. Awesome.

[Shoomakan]

Damn.. 640@ the wheels in that Volvo. Awesome.

Right?! I had no idea M60's were as strong as Supra (2JZ-GTE) engines. They also make similar power on stock internals.