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Thread: DeadPool DEFEATED! -- 540i6 Front Mount Turbo Build

  1. #51
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    98 540 6, SC'ed, 16psi
    Is Dimas twin scroll? I see the crossover connecting at the turbo flange and dual waste gates.
    98 540i 6, 525 whp, 120 mph 1/4, V3 Si S/C'er @16 psi, W/A I/C, Water/Meth, Supersprint Headers, HJS Cats, 3" Custom Exhaust, UUC Twin Disc, Wavetrac LSD, GC Coil Overs, Monoball TA, AEM FP, Aeromotive FPR, AEM Failsafe AFR/Boost, Style 65's w/275's, M5 Steering Box, Eibach Sways, M3 Shifter, Evans Coolant, 85 Deg Stat, PWM Fan, 10" Subs, B.A. speakers, Grom Aux/BT, Still Rolling as my DD!

  2. #52
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    Would think so from looks of it. Unless he's just using a split T4 flange cuz he had it around... and the dual WG's would be a lot of hassle and cost if you were only running single scroll turbo, no need for those at all if you were... Personally I'd be thinking a lot about an EFR turbo w integrated wastegate and bypass in order to simplify the plumbing and space utilization myself on one of these... Not super cheap option but means you don't have to deal w/ dump pipes or BOV/BPV stuff etc. etc. so you get some of it back in costs and a lot in fab time.
    2003 M3CicM6 TiAg
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    2008 Audi A3 2.0T DSG (the daily beater)
    2014 BMW X1 xDrive28i (wifemobile)

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  3. #53
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    GG, good point on expense and space needed for those TiAL 44s. That would suck! I kind of wonder why he thinks he needs so much wastegate too, unless he's running a rather smallish turbine side...

    Hey Chris, what do you non-VANOS S/C guys do to hold the IAC/ICV (whatever it's called on these cars) from blowing out of the intake manifold? It's not held in there very securely from the looks of things, so I anticipate wanting to improve that situation a bit.

    Also speaking of WGs, the design I had in my head for where I was going to put mine doesn't look like it will work, so I have to make a minor redesign when I fab that up

  4. #54
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    98 540 6, SC'ed, 16psi
    Zip tie FTW! Old pic, but here you go. Yeah, once I went higher boost, there was an exciting moment when it blew out. I thought I blew the motor lol.

    2016-12-05 09.16.17.jpg

    I like that your keeping ac. Going TS takes way more space. I agree with GG that EFR likely best route. Interested to see what you come up with on the WG.
    98 540i 6, 525 whp, 120 mph 1/4, V3 Si S/C'er @16 psi, W/A I/C, Water/Meth, Supersprint Headers, HJS Cats, 3" Custom Exhaust, UUC Twin Disc, Wavetrac LSD, GC Coil Overs, Monoball TA, AEM FP, Aeromotive FPR, AEM Failsafe AFR/Boost, Style 65's w/275's, M5 Steering Box, Eibach Sways, M3 Shifter, Evans Coolant, 85 Deg Stat, PWM Fan, 10" Subs, B.A. speakers, Grom Aux/BT, Still Rolling as my DD!

  5. #55
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    Zip tie, YES!!

    That's actually what I was planning to do, but I had a moment of thinking that maybe I should try to be a bit less of a hack than normal... Hahaha.. So is the zip tie solution what the S/C companies include in their kits for this purpose?

    Regarding the A/C thing, this car just doesn't seem to want to be without it. Many cars I've had over the years seemed fine without it, but not the e39 540. It sort of tends to be a car that I'm always running the A/C in unless it's one of those days when I have the steering wheel heater on. It's possible that my climate control system is screwed up in it, but I don't really think so.

    And anyway, I already have my LRS for uncivilized shenanigans. Since I'm at least 85% uncivilized, that's probably what I will continue to gravitate to unless I make this 540 quite the hooligan.

  6. #56
    geargrinder's Avatar
    geargrinder is offline Having No Trouble Here BMW CCA Member
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    Yeah for Turbo pressures might need to amp that mounting up a little bit.. But a hose clamp might be enough!
    2003 M3CicM6 TiAg
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    2008 Audi A3 2.0T DSG (the daily beater)
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  7. #57
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    Now that's my kind of thinking! Alright, I'll consider that subject handled for now.

  8. #58
    geargrinder's Avatar
    geargrinder is offline Having No Trouble Here BMW CCA Member
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    Like this 8374 in the .92AR variant? Big old EFR turbo w/ integral WG & BPV, on-board boost control solenoid included, twin-scroll ceramic ball-bearings, anti-surge comp housing, nomnomnom all the goodies...

    http://www.full-race.com/store/efr-s...-turbo-2.html/

    But TP already has his budget turbo all sliced up so this would have to be for somebody else's attempt at beating the DeadPool. Reminds me I better add you to the deadpool
    2003 M3CicM6 TiAg
    2002 540iT Sport Vortech S/C 6MT LSD TiAg
    2008 Audi A3 2.0T DSG (the daily beater)
    2014 BMW X1 xDrive28i (wifemobile)

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  9. #59
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    GOOD LORD that's an expensive mutha!! Definitely not my style haha.

    But wait, does a contestant go in the deadpool before they fail, or am I considered to already have failed since I have very little to show for the better part of a year that this build has been in progress?

  10. #60
    geargrinder's Avatar
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    re-read the deadpool. all declared big power V8 builds go there, if they succeed they get celebrated... if not... deadpool.

    - - - Updated - - -

    BTW I'm willing to re-activate any deadpool builds that get fired up again...just... most of them don't...

    I've put Wagons on Deadpool status cuz we ain't seein much REAL action - TP is raising the bar here...
    2003 M3CicM6 TiAg
    2002 540iT Sport Vortech S/C 6MT LSD TiAg
    2008 Audi A3 2.0T DSG (the daily beater)
    2014 BMW X1 xDrive28i (wifemobile)

    Former:

    1985 MB Euro graymarket 300SL
    1995.5 Audi S6 Avant (utility/winter billetturbobattlewagen)


  11. #61
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    By the way, on the topic of heat management and packaging, I think I decided last night that I am going to initially wrap the hotside parts I'm making with some DEI titanium wrap. At the point that I have everything sorted out and the design seems to be working, I will consider tearing it down and getting a good ceramic coating on it all. Currently I'm not planning to wrap the driver's side primary Ys, or the secondary Y that leads into my crossover pipe, since those are all factory dual wall stainless tubing. Well, that reason plus the fact that I've been too lazy to take the driver's side primaries off of the engine...

    - - - Updated - - -

    Quote Originally Posted by geargrinder View Post
    re-read the deadpool. all declared big power V8 builds go there, if they succeed they get celebrated... if not... deadpool.

    - - - Updated - - -

    BTW I'm willing to re-activate any deadpool builds that get fired up again...just... most of them don't...

    I've put Wagons on Deadpool status cuz we ain't seein much REAL action - TP is raising the bar here...
    Haha, sounds good!

  12. #62
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    98 540 6, SC'ed, 16psi
    Wow that's one pricey turbo. But if you add up all the wg's and bov, piping work, etc, it's likely not that bad. Ball bearing quick spool etc etc. Wow.
    98 540i 6, 525 whp, 120 mph 1/4, V3 Si S/C'er @16 psi, W/A I/C, Water/Meth, Supersprint Headers, HJS Cats, 3" Custom Exhaust, UUC Twin Disc, Wavetrac LSD, GC Coil Overs, Monoball TA, AEM FP, Aeromotive FPR, AEM Failsafe AFR/Boost, Style 65's w/275's, M5 Steering Box, Eibach Sways, M3 Shifter, Evans Coolant, 85 Deg Stat, PWM Fan, 10" Subs, B.A. speakers, Grom Aux/BT, Still Rolling as my DD!

  13. #63
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    Yeah, good point. If you compare all of the features against good quality stuff, this turbo isn't unreasonably priced assuming it all works as well as it's supposed to. A nice all-in-one package to make big powa.

  14. #64
    geargrinder's Avatar
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    Yep. That's the debate you see on the F/I forums about them usually... so expensive but wait... take out the cost of a WG and a BPV/BOV and all the fab and....

    I'm sure soon enough we'll see cheap chinese knock offs of those but of course that'll be take your chances stuff...
    2003 M3CicM6 TiAg
    2002 540iT Sport Vortech S/C 6MT LSD TiAg
    2008 Audi A3 2.0T DSG (the daily beater)
    2014 BMW X1 xDrive28i (wifemobile)

    Former:

    1985 MB Euro graymarket 300SL
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  15. #65
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    [QUOTE=BTW I'm willing to re-activate any deadpool builds that get fired up again...just... most of them don't...

    I've put Wagons on Deadpool status cuz we ain't seein much REAL action - TP is raising the bar here... [/QUOTE]

    Does that mean i get re-activated as mine is back up and running but with no numbers to boast about yet ?
    1999 540 Auto with Eaton M112 supercharger
    Airlift 3H/P management, M5 steering box, M5 LSD, Eibach/Dinan front and rear anti roll bars, PM Modifich door boards, 4 Eton 6.5s, Sound Magus VS3500.1, 2 x 10" Kove audio subs, Alpine ICS X7 Headunit, 19" BBS Hammer Sports RT245/RT246, Muffler delete, electric coolant fan.

  16. #66
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    Quote Originally Posted by Kenny1958 View Post
    Does that mean i get re-activated as mine is back up and running but with no numbers to boast about yet ?
    If it will impel you to get us some performance numbers from your setup, then I vote to re-activate you! Lol. Geargrinder, is there a voting process for which I can apply? Mmmm, beer!

  17. #67
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    I really want to be in a position to oblige but I ain't going nowhere near a dyno untill my son goes back to Finland in mid Jan. It's running well but I don't get enough time out with it, due to work and now, winter conditions.

    Sent from my SM-G920F using Tapatalk
    1999 540 Auto with Eaton M112 supercharger
    Airlift 3H/P management, M5 steering box, M5 LSD, Eibach/Dinan front and rear anti roll bars, PM Modifich door boards, 4 Eton 6.5s, Sound Magus VS3500.1, 2 x 10" Kove audio subs, Alpine ICS X7 Headunit, 19" BBS Hammer Sports RT245/RT246, Muffler delete, electric coolant fan.

  18. #68
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  19. #69
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    While very humorous, I am opting to lay low to avoid online abuse. Two complete motors built and dead 540's everywhere must count for something in the way of progress. New clutch going on now and engine back in for test fire as there's no "break in". And yeah I want it done too, but these projects consume money. I'm already looking at other vehicles which might receive this new love. A supercharged all aluminum hemi of a different mother in a traditional hot rod. Like a reverse LS swap.

  20. #70
    geargrinder's Avatar
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    Kenny you've always had "rock-on status" on the Deadpool because you had a car than ran for any notable time at all.
    2003 M3CicM6 TiAg
    2002 540iT Sport Vortech S/C 6MT LSD TiAg
    2008 Audi A3 2.0T DSG (the daily beater)
    2014 BMW X1 xDrive28i (wifemobile)

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  21. #71
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    Quote Originally Posted by wagons ho View Post
    While very humorous, I am opting to lay low to avoid online abuse. Two complete motors built and dead 540's everywhere must count for something in the way of progress. New clutch going on now and engine back in for test fire as there's no "break in". And yeah I want it done too, but these projects consume money. I'm already looking at other vehicles which might receive this new love. A supercharged all aluminum hemi of a different mother in a traditional hot rod. Like a reverse LS swap.
    Well, it does sound like you make progress all on your own, which I haven't been between April and about the time I started this thread to help motivate me and keep me on track. But come on, who doesn't love some online abuse?!?! Lol

    So what other vehicles are you thinking might be cool recipients for an M62 transplant? That is a great sounding idea.

    - - - Updated - - -

    Oh, and since the weather has turned so nasty here recently, I have turned my attention back to some of the stuff I can do inside, like building my MegaSquirt3+MS3X setup. Seems I bought most of this stuff just about a year ago when it looked like this:

    _1180560-2.jpg

    I got some of it done last year before I got distracted, and recently I have begun to make a little bit more progress on it. Some people can really knock these out, but I tend to have to work a bit more methodically since I am always thinking I've let my mind wander a bit, and have thereby made a mistake on something. At any rate, it's coming along:

    P1120159.jpg

    IMG_1221.jpg

    P1120162.jpg

    Hopefully I can work up some gumption soon to get back out in the garage and at least take some pictures of the finished (?) up-pipe and the mostly finished crossover pipe. Things are moving along decently I guess.

  22. #72
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    The Mega stuff looks interesting. Nice board holder too, I should really get one.
    Me thinks you should do some chopping to the hood.........like this guy did.

    image.jpg

    image.jpg

  23. #73
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    Man Jim, I really wish you guys would stop tempting me! Believe me, I've considered it haha. But currently I have another idea for something similar to that but more awesome for the LRS. Gotta get the 540 running before I can have the REAL fun with the LRS.

  24. #74
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    So that's the DIY version! looks like a fair amount of work with lots of soldering and trimming. Like an old Heath Kit from way way back. At least it can be done indoors in total comfort and your saving some good $$ doing the DIY version. I assume the main processors have holders so no soldering of sensitive IC's? I do like your holder and mag glass set up.

    For winter work, if my feet stay warm, I'm good. I wear thick socks and snow boots plus long johns. I'm usually fine until the garage starts to get really cold.

    Looking forward to your progress shots. Yours will have AC and Dima's wont IIRC. AC FTW!
    98 540i 6, 525 whp, 120 mph 1/4, V3 Si S/C'er @16 psi, W/A I/C, Water/Meth, Supersprint Headers, HJS Cats, 3" Custom Exhaust, UUC Twin Disc, Wavetrac LSD, GC Coil Overs, Monoball TA, AEM FP, Aeromotive FPR, AEM Failsafe AFR/Boost, Style 65's w/275's, M5 Steering Box, Eibach Sways, M3 Shifter, Evans Coolant, 85 Deg Stat, PWM Fan, 10" Subs, B.A. speakers, Grom Aux/BT, Still Rolling as my DD!

  25. #75
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    This project looks killer!!! I just happened to wonder over here because of my daily driver, and BAM. Im reading a thread with all of my favorite things. V8's, turbos, and standalones.

    Since im here, ill throw in my 2 cents.

    The EFR's are sick. The internal gate is a complete joke and does not work for any reasonable amount of boost, even with a 2 port turbosmart actuator.

    In my car, the turbos are rigid to the engine. The manifolds are all rigid, turbos bolted right to the ends of them and then they are braced from the collector to the heads. The only place i have flex sections are in the downpipes between the rad and front of the engine. I know our layouts are different (single/twin) but my point is that you dont need much.

    Whats your reservation with allowing the MS handle the ICV? 3 wire PWM is hands down the easiest method of idle control and very easy to setup.

    Is it possible to run the stock DME also? Leave the MAF in there, maybe resist it down so it doesnt see much and take control of everything else?
    Last edited by dburt86; 12-12-2016 at 03:43 PM.
    328i Sedan Twin s366's, 6.0LS, TH400, MS3 Ultimate
    9.20 at 150 on 22psi

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