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Thread: Build thread - taking the road less traveled by

  1. #26
    Join Date
    Jul 2009
    Location
    Bellingham, WA
    Posts
    364
    My Cars
    1998 M3, 2001 530i
    My problem is a bit more serious than I first thought:

    0428191447.jpg

    The bottom of the #8 stud shows necking down, so failure by tensile overload at about 83 ft-lbs with a new calibrated torque wrench. The nuts on 7 and 8 had both started to strip.

    I've found some references that ARP changed their torque specs 2-3 years ago because they started shipping a slipperier lubricant that allows a higher load to be applied with a lower torque value. Therefore, I believe I have over-torqued my studs by following outdated information.

    I'm going to buy another stud kit and save 10 of these studs that are still good to use in the M42 I'm building on my engine stand, which may eventually get a turbo (It's bored and decompressed with M44 pistons, and has the same size head bolts.) In fact, I think I will step back from this project until the new stud kit gets here, probably Tuesday.

  2. #27
    Join Date
    Jul 2009
    Location
    Bellingham, WA
    Posts
    364
    My Cars
    1998 M3, 2001 530i
    I got the MAF and air filter I've decided to use. The sensor is a Hitachi OEM slot type sensor for a 350Z, and it's going in an Airaid DIY 3.5" housing with an Airaid filter.

    0429191926.jpg

    The inner diameter of the housing is 3.125, so with the maf scaling curve for this sensor with no resistor on the signal wire, it can measure 1224 kg/hr of air before it maxes out. That should be good enough for 10 psi. If I mod the bypass valve actuator for more boost, I'll need to add a resistor on the signal before I retune.

  3. #28
    Join Date
    Jul 2009
    Location
    Bellingham, WA
    Posts
    364
    My Cars
    1998 M3, 2001 530i
    I did some initial tuning in RomRaider, just scaling the maf and doing the usual rev limiter/speed limiter mods, raised idle to 800, and reduced the fuel cut cycle time for the rev limiter so it will sound like a rally car.

    Tune1.jpg

  4. #29
    Join Date
    Mar 2013
    Location
    Upstate NY
    Posts
    1,154
    My Cars
    M3
    Oh, this is neato.

  5. #30
    Join Date
    Jul 2009
    Location
    Bellingham, WA
    Posts
    364
    My Cars
    1998 M3, 2001 530i
    Feeling better about how this is going now that I have the new studs in and torqued to ARP's spec. Not much else to report, just getting the cooling system sorted out - a custom bracket is needed for the coolant reservoir because I had to ditch the stock fan shroud. Will tackle that tomorrow night and maybe get the intercooler mounted too if all goes smoothly.

    Haven't decided if I want to cut the bumper for more flow... there was a thread where a guy cut out two inches and used some fiberglass to put it back together so the opening still looked good, can't find that thread now though.

  6. #31
    Join Date
    Apr 2017
    Location
    NJ, USA
    Posts
    439
    My Cars
    '07 335I 6MT, '01 330i
    Mind sharing ARP's current Specs? Still a 3 stage torque process?
    Keep it simple: half gutted '01 330i, welded diff, BC coils, SLR Super kit

  7. #32
    Join Date
    Jul 2009
    Location
    Bellingham, WA
    Posts
    364
    My Cars
    1998 M3, 2001 530i
    Sure, its 25 - 50 - 75, upper threads and nuts lubricated with ARP lube, including nut/washer interface.

  8. #33
    Join Date
    Jul 2009
    Location
    Bellingham, WA
    Posts
    364
    My Cars
    1998 M3, 2001 530i
    Exhaust manifolds took most of my evening to install. I fabbed up this mounting bracket for the Mishimoto tank though, just needs to be painted.

    0502192244_HDR.jpg

  9. #34
    Join Date
    Apr 2006
    Location
    Fall City ,Wa
    Posts
    1,706
    My Cars
    E36 Turbo, E39 M5
    Very cool love the build! So this is a 2.0L blower anyone know what size they used on the old Eurosport kits?

  10. #35
    Join Date
    Jun 2005
    Location
    New England
    Posts
    25,402
    My Cars
    F90 M5; E36 M3 Turbo
    1.6 or 1.7L.

    I think Tanks95 has a 2.0L twin screw modified version of the Eurosport kit. As I recall he is making around 500 rwhp. Not sure how much boost.
    Last edited by pbonsalb; 05-03-2019 at 12:10 PM.

  11. #36
    Join Date
    Apr 2006
    Location
    Fall City ,Wa
    Posts
    1,706
    My Cars
    E36 Turbo, E39 M5
    Thanks 1.7L sounds familiar. For a car in a mild climate and street use only I wonder if you could get away with meth injection only to cool the charge?

  12. #37
    Join Date
    Jul 2009
    Location
    Bellingham, WA
    Posts
    364
    My Cars
    1998 M3, 2001 530i
    No experience with injection cooling, but with the 2.0 underdriven by 25%, a big intercooler, and 9.1:1 compression, I think I should be able to run reasonable timing on the 92 octane we have here.

  13. #38
    Join Date
    Jul 2009
    Location
    Bellingham, WA
    Posts
    364
    My Cars
    1998 M3, 2001 530i
    I just remembered, if I delete or hide my radar detector, I might be able to get some 98 at some of the Shell stations in Vancouver, BC... About 30 minutes away. Got to get the tune dialed first, of course. I'll get a baseline, tune it for the M50 manifold, then add the new MAF, get the scaling dialed, swap injectors and adjust for those, and by that time the blower kit should be here. If I get a good tune for stock S52 + M50 mani + catback/CAI, I'll post it up, I feel like that should be in the public domain - It's a common low budget setup.

  14. #39
    Join Date
    Jul 2009
    Location
    Bellingham, WA
    Posts
    364
    My Cars
    1998 M3, 2001 530i
    The passenger side charge piping is blocked by a little round aluminum AC filter/drier tank (I think that's what it's for). The only direction it can be moved is up or downwards, because it's right in front of the wheel well and there are two hard lines connected to it that can't be disconnected without losing the refrigerant. I made some 2 inch spacers from aluminum round tubing and grabbed 4 65mm M6-1.0 bolts and washers.

    0505191226.jpg

    Installed:
    0505191240.jpg

    Now my 2.5" pipe fits, but I need to cut some more out of the bumper beam. I don't mind, it offsets the increased weight of the IC hanging off the front end somewhat. Mental note to double check that the AC hard lines are not rubbing on anything.

    ***Edit*** The brake duct had to be notched in the top about an inch deep due to interference with the AC reservoir tank.
    Last edited by mechanicalzen; 06-06-2019 at 10:23 PM. Reason: new info

  15. #40
    Join Date
    Jul 2009
    Location
    Bellingham, WA
    Posts
    364
    My Cars
    1998 M3, 2001 530i
    Final cuts on the bumper beam:
    0505191357.jpg

    Test fit intercooler for clearance (6.5"-7" is how much room there is below the beam to fit inside the bumper):
    0505191421.jpg

    The IC came with two 14 gauge galvanized steel brackets with slots that are too small for the bolt size provided. I decided to weld one end of each bracket to the inside of the nose panel, which is 16 gauge steel.
    Weld location:
    0505191441.jpg

    I put a 60 degree bend at the other end of each bracket:
    0505191446.jpg

    And drilled out the slots:
    0505191501.jpg

    Threw out the crappy bolts that came with the IC and grabbed a couple of grade 8.8s and lock washers.

    - - - Updated - - -
    The welds were tricky, hard to get the torch close enough inside the nose panel, but it turned out OK.
    And the intercooler is now mounted for good.
    Attachment 651070

    Actually I think I might cut the beam one more time so more air can get up behind it and through the top of the IC.
    Last edited by mechanicalzen; 05-05-2019 at 10:23 PM.

  16. #41
    Join Date
    Jul 2009
    Location
    Bellingham, WA
    Posts
    364
    My Cars
    1998 M3, 2001 530i
    From previous post:
    0505191630.jpg

    Engine is now buttoned up except for the intake side. Tested out one option for the discharge to IC pipe. I need to find out if the RomRaider XML includes the parameter for the delay between the MAF readings and the air entering the cylinders.

    0505191948_resized.jpg
    Last edited by mechanicalzen; 05-06-2019 at 01:28 AM.

  17. #42
    Join Date
    Jul 2009
    Location
    Bellingham, WA
    Posts
    364
    My Cars
    1998 M3, 2001 530i
    Brief update: engine is now back together and running again, but very roughly. The gas in the tank is 7 months old. I need to fix that and double check the vacuum/sensor connections. I laid up some fiberglass in the bumper opening to duct air through the intercooler, and I had some lidar jammers in the lower grill that had to be relocated. I installed the RallyRoad gauge pod with an AEM UEGO wideband and an Innovate boost gauge/shift light.

  18. #43
    Join Date
    Jul 2005
    Location
    California
    Posts
    758
    My Cars
    Bima
    is lidar what cops use now?

  19. #44
    Join Date
    Jul 2009
    Location
    Bellingham, WA
    Posts
    364
    My Cars
    1998 M3, 2001 530i
    Quote Originally Posted by Robocop View Post
    is lidar what cops use now?
    Honestly, I haven't been keeping up with police tech... I was clocked with lidar by WA state patrol back in 2012 or so, and successfully jammed it for about 5 seconds. Seems like the sheriffs out in the rural areas were still using radar back then. Where I live now, there's always someone doing 85-90 mph on I-5, and the state cops only drive up this far a few times a month it seems like. I mostly use Waze now when in a hurry, but I'm keeping the old integrated radar/lidar system as a nice "period" modification, along with the old chirpy aftermarket alarm/keyless entry system.

  20. #45
    Join Date
    Dec 2013
    Location
    Raleigh
    Posts
    81
    My Cars
    1993 325is
    Quote Originally Posted by mechanicalzen View Post
    Sure, its 25 - 50 - 75, upper threads and nuts lubricated with ARP lube, including nut/washer interface.

    Use arps old spec ending in 85 ftlbs. theres a thread on here somewhere with them stating 75 is too little for the cutring. people were having coolant seeping issues. me included.

  21. #46
    Join Date
    Jul 2009
    Location
    Bellingham, WA
    Posts
    364
    My Cars
    1998 M3, 2001 530i
    Quote Originally Posted by glockroulette View Post
    Use arps old spec ending in 85 ftlbs. theres a thread on here somewhere with them stating 75 is too little for the cutring. people were having coolant seeping issues. me included.
    I have to disagree with that, because I went to 85 ft lbs the first time and one stud failed from tensile overload at 83 ft lbs (pic posted earlier in the thread). The new lubricant that comes with studs transfers too much force to the stud to go to 85. If 85 is not enough, the only solution is to go to 11mm, but with this lube, 75 should be fine. My torque wrench is new and calibrated, btw.

  22. #47
    Join Date
    Jun 2005
    Location
    New England
    Posts
    25,402
    My Cars
    F90 M5; E36 M3 Turbo
    I remember the old days when these studs came out and the spec was a certain lbs and then two 90s. The result was something like 120 lbs. I did several line that and never had an issue. I think it was after the new ARP lube that the torque became a fixed number of lbs.

  23. #48
    Join Date
    Jul 2009
    Location
    Bellingham, WA
    Posts
    364
    My Cars
    1998 M3, 2001 530i
    Update - chasing issues. My fuel pressure appears to be too high. 55 psi at idle, doesn't change when unplugging the vacuum/pressure line. This thread https://www.bimmerforums.com/forum/s...pressure/page3 indicates that an aftermarket high flow pump may overpower the stock FPR. Going to order an adjustable FPR now.

  24. #49
    Join Date
    Jul 2009
    Location
    Bellingham, WA
    Posts
    364
    My Cars
    1998 M3, 2001 530i
    Big update - Car is finally running correctly.

    I had connected the harness in such a way that the crank position sensor was not getting the 12v it needs - that was the primary issue. I also think I had an obstruction in the fuel return line, which I cleared by clamping the return line shut, letting the pressure build up, and then releasing the clamp, the resulting surge cleared the line out.

    0527192033.jpg
    Quality piece as always by Aeromotive. It fit in the stock location without too much fuss. I set it to 3.5 bar and the car feels strong, even with the lowered compression. I removed the 3/2 valve and stock regulator, and deleted the secondary air injection system, which was not working and throwing codes. These can be deleted from the tune with RomRaider. I will also have to delete the CCV and run a catch can since there is no room for it with the blower.

    Now I can start datalogging and do a practice tune. I emailed Hyde and my kit is supposed to ship in the next couple of weeks.

  25. #50
    Join Date
    Jul 2005
    Location
    California
    Posts
    758
    My Cars
    Bima
    that's cool.
    so after installing the fpr it was still high?
    or you cleared the clog with the stock fpr but put in the aftermarket one because u ordered it anyway?

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