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Thread: Turbo M60 e34 Big-Power Content Inside

  1. #1
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    Turbo M60 e34 Big-Power Content Inside

    Earlier this year I was talking with another form member (Jimmyz66) about turboing his e34. We were planning a move out to Seattle which was fairly close to him and so we made arrangements.

    This car has a pretty long history and he has asked that we keep it going on this forum.

    As always lets start with an outline for some of the basics. This car has been partially assembled by at least 4 shops over 8 years so some details are not readily available.

    Engine:

    • M62 Block
    • S62 Crank
    • Arrow Rods
    • M60 Heads Ported and polished
    • Darton Sleeves
    • 9.5:1 92.5mm JE pistons
    • Custom Cams
    • MLS head gaskets
    • Arp head/Main/Rod
    • RMS Supercharger setup


    Drivetrain:
    • Fx850 Twin Ceramic
    • 6 speed 420g
    • UUC Short Shifter




    The current state of the car is pretty unfortunate. It is the cleanest e34 I have ever seen, and it is halfway through what seems like 3 different builds. The car previously ran for a short time after a very long build and dynoed around 500whp.

    After talking with Jimmy, we feel his needs are to get him into a reliable platform with a bit of headroom. He has driven this car less than 500 miles in what looks like 8 years. Jimmy set the bar for this build at 600whp with hopes for more.

    Project plan:
    • Custom Stainless Turbo header
    • Single Precision 7675 turbo
    • Rework the A/W intercooler
    • Custom A/w overflow/Ice box
    • Update everything to Proper AN fittings
    • Install a standalone
    • Update the Fuel system
    • Open wastegate


    We received the car four weeks ago and were able to break ground on it a week later. We are planning for a 6 week build for this car which will put us tuning the car the last week of September.


    I could not source stainless head flanges, so i picked up some spare heads and CMM'd the head ports and designed a flange and purge block to be able to weld these nicely.

    CMM at work:
    IMG_0857w.jpg

    Flange:
    m60Render.jpg

    Purge Block:
    m60 PURGE Render.jpg

    3d printed a prototype flange to confirm fitment:
    DSC_1073.jpg

    Knocked out the head flange purge block:
    DSC_1075.jpg



    The car will be running a DTAFast Ecu, Full sequential injection, full flex fuel, running factory coils. We will be adding a huge amount of sensors to the whole package to create a very consistent and reliable car.

    We will be reworking the RMS A/W intercooler including AN lines, -4 turbo feed, new AN Fuel system using an aeromotive regulator, We will have to reroute the AC lines to match our downpipe goals, We will tie this in with the current supersprint exhaust, Open dump on the wastegate.

    We are setting the car up through a singe 50mm wastegate with a 7 pound spring.

    The goal as of now is 4 boost settings, ranging from a 550whp base setting up to an 800whp setting. Building for headroom, but trying to get the car back in his hands as soon as possible.

    Sorry I don't have any real pictures of the car I haven't taken the time to pull them off the camera. I wanted to get this out there. Future updates will have build pics!
    Last edited by vollosso; 10-06-2018 at 04:52 PM. Reason: BFC Keeps loosing my photos.......
    1989 535i - sold
    1999 Tiag/Dove M3 - sold
    1998 Turbo Arctic/black - current
    2004 TiAg/Black - Current

    PTE6870 | 1.15 ar | Hp Cover, Custom Divided T4 bottom-mount, 3.5" SS exhaust, Dual Turbosmart Compgates, Turbosmart Raceport BOV, 3.5" Treadstone Intercooler, 3.5" Vibrant resonator and muffler, Arp 2k Headstuds | Arp 2k Main studs | 87mm Je pistons | Eagle rods | 9.2:1 static compression, Ces 87mm cutring, Custom solid rear subframe bushings, Akg 85d diff bushings, 4 clutch 3.15 diff, , Poly engine mounts, UUC trans mounts W/ enforcers, 22RPD OBD2 Stock ECU id1700 E85 tune, 22RPD Big power Transmission swap w/ GS6-53

  2. #2
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    boosted 540
    Huzzah!! Finally more turbo 540s. Me and DUD have been the only ones for a while (at least in the states)
    540iT...the T is for turbo

  3. #3
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    86 325es
    Cool project. I’ve always wanted to do a max effort m62 with darton sleeves and healthy cams to run 30+ lbs of boost. For as long as I have to work for money it will never happen but it’s a fun thought experiment


    86 325es, 2.8L m50, S472sxe, MS3pro Ultimate, e85, solid rear axle, 4 link, spool, TH400 trans, Protorque converter, 28x10.5w slicks, zip ties
    Best = 9.43 @ 149.15 mph, 1.30 60 foot 28 psi boost

  4. #4
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    Time to update your profile Zack. And that thing is going to be a beast!!

  5. #5
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    Quote Originally Posted by jakermac View Post
    Time to update your profile Zack. And that thing is going to be a beast!!
    Updated!

    Check out what just came in the mail. UPS working slow today.



    1989 535i - sold
    1999 Tiag/Dove M3 - sold
    1998 Turbo Arctic/black - current
    2004 TiAg/Black - Current

    PTE6870 | 1.15 ar | Hp Cover, Custom Divided T4 bottom-mount, 3.5" SS exhaust, Dual Turbosmart Compgates, Turbosmart Raceport BOV, 3.5" Treadstone Intercooler, 3.5" Vibrant resonator and muffler, Arp 2k Headstuds | Arp 2k Main studs | 87mm Je pistons | Eagle rods | 9.2:1 static compression, Ces 87mm cutring, Custom solid rear subframe bushings, Akg 85d diff bushings, 4 clutch 3.15 diff, , Poly engine mounts, UUC trans mounts W/ enforcers, 22RPD OBD2 Stock ECU id1700 E85 tune, 22RPD Big power Transmission swap w/ GS6-53

  6. #6
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    It will be nice to see this car and engine actually up and running well. Anyone whos been around a while knows its been a rough go of it.

    Was the car previously running a standalone? I can’t recall.

    I would love to come check this car out. Maybe a good excuse for a PNW get together?
    -Nick
    91 E30 M42 on VEMS

    Turbo Camshaft Thread

  7. #7
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    Quote Originally Posted by wazzu70 View Post
    It will be nice to see this car and engine actually up and running well. Anyone whos been around a while knows its been a rough go of it.

    Was the car previously running a standalone? I cant recall.

    I would love to come check this car out. Maybe a good excuse for a PNW get together?
    It was stock ecu. I was specifically asked to do a standalone, and honestly I think its a good car for it.

    I did disassemble a bit of the ecu last night. Grabbed stock ignition, fueling, dwell, cranking and a few other things to set the ecu up easier. Basically the same as other motronic ecus. I am not a huge fan of the motronic control strategy in boosted applications.

    We should absolutely get everyone together.


    Sent from my iPhone using Tapatalk
    1989 535i - sold
    1999 Tiag/Dove M3 - sold
    1998 Turbo Arctic/black - current
    2004 TiAg/Black - Current

    PTE6870 | 1.15 ar | Hp Cover, Custom Divided T4 bottom-mount, 3.5" SS exhaust, Dual Turbosmart Compgates, Turbosmart Raceport BOV, 3.5" Treadstone Intercooler, 3.5" Vibrant resonator and muffler, Arp 2k Headstuds | Arp 2k Main studs | 87mm Je pistons | Eagle rods | 9.2:1 static compression, Ces 87mm cutring, Custom solid rear subframe bushings, Akg 85d diff bushings, 4 clutch 3.15 diff, , Poly engine mounts, UUC trans mounts W/ enforcers, 22RPD OBD2 Stock ECU id1700 E85 tune, 22RPD Big power Transmission swap w/ GS6-53

  8. #8
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    Quote Originally Posted by vollosso View Post
    We should absolutely get everyone together.
    I'm in!

  9. #9
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    Quote Originally Posted by vollosso View Post
    It was stock ecu. I was specifically asked to do a standalone, and honestly I think it’s a good car for it.

    I did disassemble a bit of the ecu last night. Grabbed stock ignition, fueling, dwell, cranking and a few other things to set the ecu up easier. Basically the same as other motronic ecus. I am not a huge fan of the motronic control strategy in boosted applications.

    We should absolutely get everyone together.


    Sent from my iPhone using Tapatalk
    In this case standalone is absolutely the way to go IMO. I think the main issue the car had in the past was a lack of good cotrol. The best hardware does not mean chit if its not properly controlled!
    -Nick
    91 E30 M42 on VEMS

    Turbo Camshaft Thread

  10. #10
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    Okay, can vouch for said car, actually saw this in person and it’s super cool. Zack also cool in real life lol
    CBlock


  11. #11
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    Quote Originally Posted by motorokr718 View Post
    Huzzah!! Finally more turbo 540s. Me and DUD have been the only ones for a while (at least in the states)
    https://www.bimmerforums.com/forum/s...ight=Dead+pool
    98 540i 6, 525 whp, 120 mph 1/4, V3 Si S/C'er @16 psi, W/A I/C, Water/Meth, Supersprint, HJS, 3" Ex, UUC Twin Disc, Wavetrac LSD, AEM FP, Aeromotive FPR, AEM Failsafe AFR/Boost, 65's w/275's, M5 Box, Eibach, M3 Shifter, Evans, 85 Deg Stat, PWM Fan, 10" Subs, B.A. speakers, Grom Aux/BT, Still Rolling as my DD!

  12. #12
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    boosted 540
    ...the only *e34* 540s. Well aware of tptrsn build. Haha


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    540iT...the T is for turbo

  13. #13
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    It will be nice to see the bmw v8 extended to the point of making big power. I wish everyone involved welll.
    BMWs
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    97 E36 M3 euro SC

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  14. #14
    Def's Avatar
    Def is offline Lead Disagreement Eng PE
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    Quote Originally Posted by jakermac View Post
    I'm in!
    Me too! (even though I'm late seeing this)

  15. #15
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    Turbo m60, following this for future reference haha, looks amazing so far!


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  16. #16
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    Zack, many heartfelt thanks for taking on this project for me. Cali is sorely lacking in good, reliable BMW custom tuners for the BMW V8s. Hell, I remember years back when there was no one who could make a decent turbo kit for my E34 535i. I have been through a lot, did not listen to members regarding Osh/RMS, but have always persevered and knew someday it would work out. I owe everything to Zack and am even happier that I have the opportunity to switch from supercharger to turbo. I have seen the light and am grateful. I upgraded the suspension and exhaust on my Porsche 997 Carrera S and decided not to upgrade the engine performance and spend the money on getting my 540i right. I think I made the right choice.
    Last edited by jimmyz66; 09-26-2018 at 07:36 PM.
    '95 540i/6 mit Borg Warner S400sxe/4.9L M62/JE pistons/Arrow rods/custom cams/S62 crankshaft
    Porsche 997 Carrera S-my daily

  17. #17
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    Any updates?
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    1998 M3/4/5 - TCK SA, Vorshlag Camber Plates, X-Brace, RR Strut Bar, Turner Rear Camber Arms, SSK, 3.38LSD, MM Underpanel, 17x9 Forgeline ZX3R
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    2009 GL550 - Stock
    IG: sleep_eat_drive

    Past: SC'd 95 540/6, CSL'd E46 M3, Big turbo 88 951, Lifted 97 Land Cruiser, Kleeman K2 E55 Wagon

  18. #18
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    Quote Originally Posted by E34nication View Post
    Any updates?
    Tomorrow


    Sent from my iPhone using Tapatalk
    1989 535i - sold
    1999 Tiag/Dove M3 - sold
    1998 Turbo Arctic/black - current
    2004 TiAg/Black - Current

    PTE6870 | 1.15 ar | Hp Cover, Custom Divided T4 bottom-mount, 3.5" SS exhaust, Dual Turbosmart Compgates, Turbosmart Raceport BOV, 3.5" Treadstone Intercooler, 3.5" Vibrant resonator and muffler, Arp 2k Headstuds | Arp 2k Main studs | 87mm Je pistons | Eagle rods | 9.2:1 static compression, Ces 87mm cutring, Custom solid rear subframe bushings, Akg 85d diff bushings, 4 clutch 3.15 diff, , Poly engine mounts, UUC trans mounts W/ enforcers, 22RPD OBD2 Stock ECU id1700 E85 tune, 22RPD Big power Transmission swap w/ GS6-53

  19. #19
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    So I have had a void since photobucket and haven’t wanted to deal with it, so today I created a directory on the website and i will now upload pictures to it and can finally get back to posting images. I manually cut these images to half size but may need to go smaller, we will learn as we go!

    So we have been very busy lately, between releasing our e46 m3 tunes (which have been a success, netting at least 20whp) and developing e60 m5 tunes (Which will come out officially later this month) so I personally apologize for the lack of updates.

    Honestly we have been waiting for a turbo for what feels like months. With the recent success of our 6870 car we were keen to try the precision 7675. We ordered the turbo maybe a week after receiving the car but it has been on backorder since. Just last week we called and cancelled the turbo as we couldn't afford any more delays and we ended up ordering a Borg Warner S400sxe. I made a bunch of calls to friends that live in the v8 world, specifically to some tuners that work directly with coyote motors and talked to them about what turbine they like on their 5.0L 4 valve motors. General consensus was the s400sxe 83mm turbine was the best. We received the BW in 3 days of order, arriving just yesterday.

    For reference Coyote guys are running this exact turbo to a bit over 1000whp with full boost ~25psi around 3500 rpm. A lot of things come into play but that is an excellent benchmark.

    We ended up ordering the 76mm S400sxe, PN 14009097006 paired with a 1.10 ar turbine housing. This is a very nice turbo. Excellent castings, Vband housing connections, Billet wheel. As you dig deeper into wheel designs you find that they are as much art as they are science, and I’m really excited to try these out.




    And so you can have a size reference we put it next to something you should all know.....



    The flanges I had water-jet cut never loaded on the first page, they turned out really nice. I had some extras cut if anyone else wants a flange set or a manifold.





    While we were waiting on the turbo we went ahead and made the manifold, we went with a tubular log style manifold. We used 1.75" primaries. Better manifolds could probably be made, but this is a really compact way to package this setup and these manifolds have been proven to thousands of hp. We went a bit further and jigged up the "primaries" to do the best inlet/merge one could achieve, without getting completely carried away. So this inlet allows us to direct the sonic pulse (from the valve lift) pretty effectively. This should minimize cylinder competition. The mass flow at lower rpm will probably stagnate a bit as we jump in chamber volume pretty aggressively.

    The purge block performed excellently.





    Went ahead and started playing with the turbo and how it will fit in the chassis:







    Then fabricated the flange and "up-pipe" to the turbo. It is always fun trying to make a round tube a rounded rectangle. Lightly/quickly welded the inside of the flange to create a smooth transition. If you do it quickly and on low enough heat it won’t create any oxidation on the outside of the pipe. I then went back and welded the outside of the flange:



    SO that's about it for now. As we will be making more photogenic progress in the coming week or so I’ll try to update more regularly.
    Last edited by vollosso; 10-06-2018 at 08:03 PM.
    1989 535i - sold
    1999 Tiag/Dove M3 - sold
    1998 Turbo Arctic/black - current
    2004 TiAg/Black - Current

    PTE6870 | 1.15 ar | Hp Cover, Custom Divided T4 bottom-mount, 3.5" SS exhaust, Dual Turbosmart Compgates, Turbosmart Raceport BOV, 3.5" Treadstone Intercooler, 3.5" Vibrant resonator and muffler, Arp 2k Headstuds | Arp 2k Main studs | 87mm Je pistons | Eagle rods | 9.2:1 static compression, Ces 87mm cutring, Custom solid rear subframe bushings, Akg 85d diff bushings, 4 clutch 3.15 diff, , Poly engine mounts, UUC trans mounts W/ enforcers, 22RPD OBD2 Stock ECU id1700 E85 tune, 22RPD Big power Transmission swap w/ GS6-53

  20. #20
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    Ah almost forgot, knocked out some fuel rails. Still have to thread them for fittings then ill clean them up. They are a bit "As machined" currently.
    1989 535i - sold
    1999 Tiag/Dove M3 - sold
    1998 Turbo Arctic/black - current
    2004 TiAg/Black - Current

    PTE6870 | 1.15 ar | Hp Cover, Custom Divided T4 bottom-mount, 3.5" SS exhaust, Dual Turbosmart Compgates, Turbosmart Raceport BOV, 3.5" Treadstone Intercooler, 3.5" Vibrant resonator and muffler, Arp 2k Headstuds | Arp 2k Main studs | 87mm Je pistons | Eagle rods | 9.2:1 static compression, Ces 87mm cutring, Custom solid rear subframe bushings, Akg 85d diff bushings, 4 clutch 3.15 diff, , Poly engine mounts, UUC trans mounts W/ enforcers, 22RPD OBD2 Stock ECU id1700 E85 tune, 22RPD Big power Transmission swap w/ GS6-53

  21. #21
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    I will be frank with you Zack. I was new to the BMW mod scene. With my E34 535i/5 I modded the heck out of it. I mean sway bars, sport swings and shocks, Miller WAR chip/MAF ( after Dinan chip and Unichip), short shift kit, custom Arc Audi stereo, M3 steering wheel, MK ! wheels. I even bought a BMW 7 series turbo kit. but could not find anyone to install and tune it. Before the Miller War chip/MAF, I was beaten on the highway by a Nissan 3.5L Maxima. 2 weeks later, I bought a used 540i with 50k miles and every item Dinan had in his cataloge including a supercharger, and had someone who was going to St. Louis and checked it out for me. Did not feel like the claimed 400+ hp when I first got on it and found out the old school Powerdyne Kevlar belt was broken. After that it went all down hill. Unichip tuner in Sacramento blew my engine on his dyno and blamed the engine as being "weak". Had an Audi shop re-tune it with new M60/M62 highbred. Still was not satisfied, so I mad the biggest mistake of my life by sending it down to RMS/Osh/Chris and they also blew up my new engine and blamed the head gasket. The racing shop that rebuilt my 4.9L M60/M62 engine said to was the fault of the so-called tuner. I brought to RMS just to get an E39 M5 after cooler, and he promised me and swore to God he knew how to tune my car. I gave him another chance and 3 years later I get my car and it dies at every stop light, runs super lean and fact my Autometer went as far as lean could go. I declined to send my car back to Osh. RK Tunes re-tunrd my engine and 150 miles later the engine blew up again. Jordan/RK Tunes said it was Osh's fault. Had the engine rebuilt again, but a little more aggressive cams and let my 540i/6 sit for over a year trying to find a quality, respected tuner.I had no luck until I read a post by vollosso. I knew in my heart and my past experience that I was in good hands with Zack and 22RPD Tuning. When I talked to him on the phone he was polite, extremely knowable, my importantly an engineer. I mean when I say he ha given me new hope in turning my E34 into a monster. He is extremely well versed on BMW's and turbo charging. In fact at first I just wanted him to tune my s/c system that I just put together (new Vortech V2h/dTi). In the back of my mind I always wanted a turbo system for it's options on different power levels and using exhaust to power the he'd unit. But honestly, I thought it would never happen because who makes a turbo kit for the E34 540i? Well, Zack changed my mind with his knowledge, personality and customer skills. I knew if I was patient I would get my car running as it should, but never in my mind did I think I would have the opportunity to have such a great forced induction system. I owe everything to Zack and Rebello Racing, who rebuilt my engine. Thank-you Zack, and not to be too syrupy, but it is an honor to meet you and have you work on my car.
    Last edited by jimmyz66; 10-09-2018 at 12:46 AM.
    '95 540i/6 mit Borg Warner S400sxe/4.9L M62/JE pistons/Arrow rods/custom cams/S62 crankshaft
    Porsche 997 Carrera S-my daily

  22. #22
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    Quote Originally Posted by jimmyz66 View Post
    I will be frank with you Zack. I was new to the BMW mod scene. With my E34 535i/5 I modded the heck out of it. I mean sway bars, sport swings and shocks, Miller WAR chip/MAF ( after Dinan chip and Unichip), short shift kit, custom Arc Audi stereo, M3 steering wheel, MK ! wheels. I even bought a BMW 7 series turbo kit. but could not find anyone to install and tune it. Before the Miller War chip/MAF, I was beaten on the highway by a Nissan 3.5L Maxima. 2 weeks later, I bought a used 540i with 50k miles and every item Dinan had in his cataloge including a supercharger, and had someone who was going to St. Louis and checked it out for me. Did not feel like the claimed 400+ hp when I first got on it and found out the old school Powerdyne Kevlar belt was broken. After that it went all down hill. Unichip tuner in Sacramento blew my engine on his dyno and blamed the engine as being "weak". Had an Audi shop re-tune it with new M60/M62 highbred. Still was not satisfied, so I mad the biggest mistake of my life by sending it down to RMS/Osh/Chris and they also blew up my new engine and blamed the head gasket. The racing shop that rebuilt my 4.9L M60/M62 engine said to was the fault of the so-called tuner. I brought to RMS just to get an E39 M5 after cooler, and he promised me and swore to God he knew how to tune my car. I gave him another chance and 3 years later I get my car and it dies at every stop light, runs super lean and fact my Autometer went as far as lean could go. I declined to send my car back to Osh. RK Tunes re-tunrd my engine and 150 miles later the engine blew up again. Jordan/RK Tunes said it was Osh's fault. Had the engine rebuilt again, but a little more aggressive cams and let my 540i/6 sit for over a year trying to find a quality, respected tuner.I had no luck until I read a post by vollosso. I knew in my heart and my past experience that I was in good hands with Zack and 22RPD Tuning. When I talked to him on the phone he was polite, extremely knowable, my importantly an engineer. I mean when I say he ha given me new hope in turning my E34 into a monster. He is extremely well versed on BMW's and turbo charging. In fact at first I just wanted him to tune my s/c system that I just put together (new Vortech V2h/dTi). In the back of my mind I always wanted a turbo system for it's options on different power levels and using exhaust to power the he'd unit. But honestly, I thought it would never happen because who makes a turbo kit for the E34 540i? Well, Zack changed my mind with his knowledge, personality and customer skills. I knew if I was patient I would get my car running as it should, but never in my mind did I think I would have the opportunity to have such a great forced induction system. I owe everything to Zack and Rebello Racing, who rebuilt my engine. Thank-you Zack, and not to be too syrupy, but it is an honor to meet you and have you work on my car.
    Wau bro, so sad storry. Hope, now these guys know what they are doing. Wish you success.

    Also, i want share my experience after many m62 engines blown. The main thing is USING good known aftermarket ECU. With standalone, you will be safe.
    e39 540i 6speed Supercharged,
    E36 v8 m62 with m60 headers, Turbp HX-40 0.6-0.5bar or 9psi, custom exhaust & Turbo manifold, injectors 440cc, ECU Invent EMS-2, Mishimoto Intercooler and oilcooler, etc

  23. #23
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    Quote Originally Posted by vollosso View Post
    Ah almost forgot, knocked out some fuel rails. Still have to thread them for fittings then ill clean them up. They are a bit "As machined" currently.

    Id be interested in a set of rails if youd be willing to make another


    Sent from my iPhone using Tapatalk
    540iT...the T is for turbo

  24. #24
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    Quote Originally Posted by motorokr718 View Post
    Id be interested in a set of rails if youd be willing to make another


    Sent from my iPhone using Tapatalk
    Of course. Email me at zack@22rpd.com


    Sent from my iPhone using Tapatalk
    1989 535i - sold
    1999 Tiag/Dove M3 - sold
    1998 Turbo Arctic/black - current
    2004 TiAg/Black - Current

    PTE6870 | 1.15 ar | Hp Cover, Custom Divided T4 bottom-mount, 3.5" SS exhaust, Dual Turbosmart Compgates, Turbosmart Raceport BOV, 3.5" Treadstone Intercooler, 3.5" Vibrant resonator and muffler, Arp 2k Headstuds | Arp 2k Main studs | 87mm Je pistons | Eagle rods | 9.2:1 static compression, Ces 87mm cutring, Custom solid rear subframe bushings, Akg 85d diff bushings, 4 clutch 3.15 diff, , Poly engine mounts, UUC trans mounts W/ enforcers, 22RPD OBD2 Stock ECU id1700 E85 tune, 22RPD Big power Transmission swap w/ GS6-53

  25. #25
    Join Date
    Apr 2011
    Location
    Boston, MA
    Posts
    377
    My Cars
    E36 M3 Turbo
    Good GOD that turbo is massive. I didn't really understand until the Brakleen can lol
    97 Turbo 3.2L M3 - Cutring / ARP - RSI Top Mount - Gt4088r - ID1300 - Tial WG - 22RPD Tuned - 93 Octane - 3.5" Stainless

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