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Thread: S54 ---> Hellrot E36 328I

  1. #101
    Join Date
    May 2009
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    Pittsburgh, PA
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    S54/E36,18 Sierra Denali
    Oil cooler mounted as well as suspension. It'll be finalized today, then I'll be able
    to drop the car and move it in and out for more work space.

    my steering wheel is clocked about 70 degrees to the right from all the work haha so I need to pull the wheel and straighten that then try to get alignment acceptable for a few test trips.

    And this Abrams CF LTW Wing,
    hellrot with exposed CF risers! Had it sent to my parents house..:mom wasn't too happy about the table haha

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    Last edited by PITT M3 RR; 11-08-2016 at 10:48 AM.

  2. #102
    Join Date
    Sep 2015
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    Stow, MA
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    1997 328i
    Wing looks good, I dig LTW's. What'd you mount the cooler to? I can't really tell from the pictures.

  3. #103
    Join Date
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    S54/E36,18 Sierra Denali
    Hey Ill grab some photos once its secured today But to quickly get into it. I removed the lower vent portion of the front upper cover. Its the part that supplies air to the E36 alternator (not needed now) and the derale cooler I ordered is the exact width of the two hard plastic ducts for the rad / fan etc...I flipped the metal clips and secured the cooler using screws from the bottom. Last will be 2 small brackets to the aluminum bumper to keep the cooler from contacting the aux fan. You can kind of see what I mean in the further away photo.

    The 45 degree fitting fit angled inside the aluminum bumper and the hose is routed down and Around the rad. This way, the front end can be removed, with out taking the cooler off as it can now just be lowered and moved away.
    Last edited by PITT M3 RR; 11-08-2016 at 11:07 AM.

  4. #104
    Join Date
    May 2009
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    S54/E36,18 Sierra Denali
    Here ya go - brackets can be seen on bottom. Dove into custom vac lines...more to come soon.
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  5. #105
    Join Date
    Mar 2004
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    USA
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    96 328is 6.0L
    Making neat brackets to the bumper is nice and clean, but I would stay away from that. In a light impact that would otherwise result in the bent bumper, you are now risking loosing your oil and making the car undrivable.

    Instead i would rotate the brackets 90* and connect them to frame rail instead. Just an observation.
    - 96 328is 6.0L. (LS1 to LS2 build thread: http://forums.bimmerforums.com/forum...ad.php?2098938)
    - 96 328is 5.7L. (LS1 build thread: http://forums.bimmerforums.com/forum....php?t=1289987)
    - 95 ///M3 6.0L. (LS2 build thread: http://forums.bimmerforums.com/forum....php?t=1619249)

    - 97 ///M3. (e46 Fender Flares/track car build thread: http://forums.bimmerforums.com/forum....php?t=1727098)
    - 96 328is (Dual Fuel Pump to Surge Tank thread: http://www.bimmerforums.com/forum/sh...ad.php?1964025)

  6. #106
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    I thought about that actually, my thought was that I'm the only one who's driving this and I'm aware of all the little mods etc...id just kill the engine impact. Even if I rotated the brackets, the fittings off the cooler are still right against the bumper support. there just isn't room with A\c and aux fan...and I'm under the impression we need the aux fan. Right?

  7. #107
    Join Date
    Mar 2004
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    96 328is 6.0L
    Correct. The Aux fan is both needed for the AC and engine cooling in slow/stop and go traffic. The clutch fan is the one that can be diched.
    - 96 328is 6.0L. (LS1 to LS2 build thread: http://forums.bimmerforums.com/forum...ad.php?2098938)
    - 96 328is 5.7L. (LS1 build thread: http://forums.bimmerforums.com/forum....php?t=1289987)
    - 95 ///M3 6.0L. (LS2 build thread: http://forums.bimmerforums.com/forum....php?t=1619249)

    - 97 ///M3. (e46 Fender Flares/track car build thread: http://forums.bimmerforums.com/forum....php?t=1727098)
    - 96 328is (Dual Fuel Pump to Surge Tank thread: http://www.bimmerforums.com/forum/sh...ad.php?1964025)

  8. #108
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    S54/E36,18 Sierra Denali
    Yea I figured, at the moment, there's a few MM clearance between the cooler and fan. It's solid. I can't think of anywhere else to mount it though and I think it would be pointless to run a smaller cooler. I guess I could always do the Z3M set up if I get the rad, but this is a fun street car for me.

  9. #109
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    S54/E36,18 Sierra Denali
    Vac line update. Turns out HD has decent options. 3/8 , 1/2 , 5/8, "shark bite" barbed fittings and PEX plumbing tube. If you heat it, it becomes mailable and presses onto fittings. I'm going to run it like this to get the car done and then see if I can make a complete vac system from scratch after.

    You can also cut the adapters from the factory tired plastic line and re plumb them (see oil separator line) 05+ ports capped.

    Also so ran the expansion tank coolant line cut from the original oem E36 line.
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    Last edited by PITT M3 RR; 11-10-2016 at 01:08 PM.

  10. #110
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    Apr 2005
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    Tampa, FL
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    97 E36M3 S54
    Are there any pros/cons to running the SMG airbox since you're not using it?

  11. #111
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    Cons : it's bigger

    pros : you can make an oil catch can out of the resiviour. I had the idea a little bit ago. I'll do it once everything else is done.

  12. #112
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    Vac lines are complete.






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    Last edited by PITT M3 RR; 11-11-2016 at 05:35 PM.

  13. #113
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    Air intake made custom from the E46 upper airbox half. Alternator vent trimmed and functional.


    The air box requires disassembly, then cutting off the extremities from the tubing. I wanted to maintain the air straightener and was able to. It was a lot of cutting but worth it.









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    Last edited by PITT M3 RR; 11-13-2016 at 08:14 PM.

  14. #114
    Join Date
    May 2009
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    S54/E36,18 Sierra Denali
    Alternator
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  15. #115
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    UT
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    98 M3/4/5
    Looking good man, how soon before it's street worthy?
    98 Estoril ///M3 4/6
    S54 swap CSL

  16. #116
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    Thanks!

    Off the top of my head

    - Belt
    - fan clutch
    - coolant vent hoses
    - coolant
    - PS fluid
    - sec 2 exhaust (technically not needed, but I want to hear the motor)

    I'll be able to drop and test drive then.

    Once thats done, with no leaks issues etc...

    - cluster (can wait now because I have both coolant temp sensors installed)
    - ltw wing and other body parts etc..

    I'm only getting over there a few days a week, wish I had more time.

    Once it's driving without issue, I'll probably redo the suspension. Custom steering Guibo I want to make etc. I have a few plans.

  17. #117
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    Some coolant lines here and check out the oil cooler placement - it's about perfec I'd say.

    Im also having trouble sourcing a belt, 60" is too long, 58" too short. Ordered a 58 3/8" for tomorrow if that doesn't work, I'll try a 59 1/4. This is with all E46 pullies except the PS which is E36. I'll update when I get it right.

    I also noticed when checking the oil today that I was at the bottom line. Got to thinking, oil cooler may have taken a bit but further more, due to the fact that I completely drained out for the mini refresh the car took 6.7 qts instead of the 6 it would normally at a change interval.

    also you can see that if you use worm clamps
    on the airbox, you need to be careful to not obstruct the movement of the throttle body assembly.

    also got 3 gallons of BMW blue antifreeze today and took apart my spare steering coupler so I can make a solid solution.
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    Last edited by PITT M3 RR; 11-15-2016 at 12:46 AM.

  18. #118
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    I'm going with a 16 inch 2000 CFM Spal fan. The fan clutch blade is too close to the top of the shroud, I won't run it without a shroud and trimming the blades is apparently dangerous. I've heard the 318i unit works, but the spal seems to be a reasonable upgrade.

    Also started on the exhaust. I had all this stuff laying around from awhile ago, so decided to see where I could take it. It's 2.25 piping and I used the 22.5 degree cut method for the bends. It's not attractive at the moment, but should clean up when blended. I've stopped where you see and ordered a mechanical pipe expander for slip fitting.

    And I think* I'm going to pick up one of those 2.25 mandrel kits from eBay. It's very time consuming to cut and weld this much.

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  19. #119
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    More

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    Forgot to add, cooling system installed, BMW blue in there, car started and ran at temp for 15 minutes!! No issues no leaks.
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    Last edited by PITT M3 RR; 11-17-2016 at 11:54 AM.

  20. #120
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    No more BMWs :(
    Nice work, you're really putting in the time! I also know how hard it is building your own exhaust as I have done it before. Keep up the good work, can't wait to see the finished product.


    -Nick


  21. #121
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    Ditch that X pipe you have, it's actually not a very good flowing X. I had one just like it on another car of mine and lost power with it compared to 2 pipes cut and welded together. Also 2.25 is probably a bit too small for the S54. 2.5 is usually the best for duals on it.
    98 Estoril ///M3 4/6
    S54 swap CSL

  22. #122
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    Quote Originally Posted by TH3 Shifty View Post
    Ditch that X pipe you have, it's actually not a very good flowing X. I had one just like it on another car of mine and lost power with it compared to 2 pipes cut and welded together. Also 2.25 is probably a bit too small for the S54. 2.5 is usually the best for duals on it.
    Agreed, go dual 2.5. I have SS V1 + SSV1 mids into the E46 OE Sec2 globbed to an E36 M3 stock muffler and holy crap is it choked and restrictive. I'm going single 3" from section 2 back next (merging SS Sec2 with AA Race exhaust E36 muffler)Also on belt...I'm pretty sure I used the stock belt with the E36 PS pulley. I had to get a different AC belt but the accessory belt I thought I left alone.Keep it up, and nice job on the air intake! That's a really clean and creative way to get the MAF signal.
    "Fear disturbs your concentration" -Sabine Schmit

    1995 BMW M3/2/5-- S54 + Mk60 DSC, California Smog Legal (Build Thread)
    1998 BMW M3/4/5 Alpine/Modena, Z3 Rack, otherwise stock-- DD without burbles
    2017 Chevy SS, Orange Blast Metallic, 6MT -- DD with burbles

  23. #123
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    Thanks for the words and help guys.

    2.5" you say? I read so much and the consensus was that's dual* 2.5 was too much and I'd lose low end. Dual 2.25 was recommended, even over single 3 or 3.5, through those were next in line. I had 24 feet of 2.5" I traded back in for this 2.25!!!!

    It was that HP vs tube diameter calc talk. I'll see if I can't pull the calculation and post it.

    "
    #9
    nando
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    Join Date: Nov 2003
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    dual 2.5" is HUGE.

    just taking sq/in to CFM isn't accurate, because the surface area of a larger single pipe is less than 2 smaller pipes, which means it flows effectively better even with the same open area.

    A single 2.5" actually flows about the same as dual 2", because although it has a little less open area (~1sq in), the surface area of the pipe is actually less, which means less friction.

    Also, you can't just add diameters to get open area. For example, two 1 1/4" pipes are not equal to a single 2.5" in area. it's almost half! (not saying anyone is doing this, it's just pointing out that the difference between 2" to 2.5" is a LOT more than it appears).

    dual 2.5" has 9.8 sq inches of open area.. that's way more than a single 3" (7sq in) and even more than a single 3.5" (9.6"). It will flow less than a 3.5" though because it has more surface area, it will also weigh more and cost more to build.

    dual 2.25" is more than plenty (it's still 8 sq inches!).. I'd still go with a single pipe personally, probably 3".
    "

    Youre right though, I see the stromung being a restriction as it goes from the 2.25 Inlet down to dual 2" I believe. I know eventually I'll have to bump that up.


    In reality an E46M 2.3" mid pipe set up with custom sec3 would be ideal. It I'll need to source that somewhere local and That'll be tough.

    Do you have that belt size; I ended up going with the 58 3/8 belt and it grabbed pretty well. I realized I was trying to fit the E36 belt, I never got an E46 belt with the motor.


    As as for the X pipe, it flows bad? Maybe I'll do the 2 45 bends joined at peak. OR just build this for now, the. Sell off the Sec 2/3 cheap to someone who may want to use it. I'll keep eveyone updated back at work so it may be a few.
    Last edited by PITT M3 RR; 11-18-2016 at 10:44 AM.

  24. #124
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    Yeah it's the design of it, it doesn't allow the air to flow on a straight path, and that X is essentially just an open box. It caused a drone hollow sound as well on a car we had. You want something like euro e36 supersprint midpipe. I bought the replica that "foler" was selling in the performance section. It's 60mm diameter polished stainless and would flow really well for the S54. I posted pics of my set up in the e36 M3 section so search my thread over there for pics and you can see the x pipe section.
    98 Estoril ///M3 4/6
    S54 swap CSL

  25. #125
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    Cool man thanks I'll check it out - I'm feeling like I'll finish this now and then build a stainless solution all the way back from scratch. This way I can sell the stromung after and the mid pipe for someone doing the swap later on. I need a new tool...mandrel bender

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