1995 E36 M3 GT Twin Turbo

Hi guys, this is the follow-up from the introducton thread

Its one of the 350 Euro GT cars, mine is number 111.
Engine is the S50B30 ITB Single vanos, with S50B32 upgraded intake manifold and lubrication system.

Here is part nr 1 http://www.bimmerfest.com/forums/sho...d.php?t=530785

By this stage the suspention was sorted, the ceramic brakes and various other stuff.. but I wanted more power..


Early 2008 I started with the install of the Twin Turbo system on stock internals. As I said the system was not a perfect design, but it was designed to run at 8psi, i ran it at 11psi. The exhaust manifolds were terrible, and made a strange engine sound, but they did the job for the time beeing.





I was using 440cc injectors and I flew in a expert tuner to tune the original BOSCH DME. The car drove reliable but soon I started to see pressure in the coolant so I upgraded to a MLS 0.140 plus ARP's.

0-200 run on this setup



There was still room for improvement.. and actually the engine (piston rings) were starting to show some wear.. so... why not do a fully built bottom end. Engine went out..


I

bought a set of CP Pistons (8.5:1), some custom made Forged connecting rods, the Walbro 255 and NGK-R 2525-9 plugs. I also got a set of VAC main and rod bearings (coated) and ARP's for the rods.


I also got in contact with a tuner in Sweden where I bought the rods and he had his friend make me a set of Tubular exhaust manifolds.


Somewhere in between I had also bought a SuperSprint De-cat midsection and the OEM X-Brace for the frunt suspention from the Cabrio

The rebuild..

Block with pistons, rods and bearings installed, mirror surface on the block ready for the stock thickness MLS.


Head re-mashined, some porting and plolishing along with new copper valve guides.


The JBRacing lightweight flywheel installed. I did not have the block painted or any of the parts specially cleaned. My car is for driving so it does not really bother me.


Engine almost done. Canio (my Italian mechanic) and my Tuner (also a pretty good engineer/mechanic) working on the engine.


Almost done.. This airbox would later explode on the welds..



Exploded intake manifold... gread build quality.:hihi


So I did like the guys in Sweden do. I modified the OEM intake for Turbo. Much better quality.



The car was tuned with the old airbox. It made 470hp/560nm at Mantehy Racing in Nurburgring. Manthey is one of the best Porsche racing specialists around. The dyno was made using the old airbox.







The car was running 12psi, there were some problems with boost leakage after I installed the OEM airbox, forgot to put the O-rings on the runners... Still, I went to SPA Francorchamps in May 2009 where the car performed well, lapping a 2:50 which is respectable for a road car. I also had installed a S2.65 differential from a 325TDS and that made the gears very tall. Potential top speed of 340km/h doing 280 in 4th. Surely not optimal for track driving... Still, I had some CSL for Lunch. (min 2:40)

http://www.youtube.com/user/farturinn#p/u/3/LMVKM0OUnP0

In the lates rebuild I had installed a Gizzmo electronic boostcontroler... that made me a bit greedy so I started pushing up the boost. Going up to 22psi. The AFR's looked ok, and so did the EGT, but something went wrong. The coolant started to pressurise in summer of 2010 so the only option was to rebuild the engine again. This time around I decided to do all the work myself. Keep in mind that I have no mechanical training or experience. I work in Private Banking..
When the engine came apart it was quite obvious that the headgasket was blown... quite badly actually for an MLS. I along with some of my friends started speculating what had gone wrong. Most likely it was due to detonation, which resulted in me beeing to agressive on the boost and the car probably running out fo fuel at the top end since the injectors were only 440cc. Still I was running almost 4.5Bar of fuel pressure.

HG badness...


This time around I decided to go with a STOCK HeadGasket from BMW and I also upgraded to ARP2000 bolts.

Head off and pistons cleaned


It was a strugle to get the head on since I was doing the job alone, I bought an engine crane and that helped.


Head on.


I also put some thermal insulation on the engine bay.


I also thermal wrapped the downpipes.




Since I had no previous experience the timing of the cams and valve adjustments were a pain in the neck. But I managed.

Almost done.. again


The RC750 injectors went in along with the Moristech Piggyback (installed it myself) and the Knock link Knock detector.

The car started up ! I was pretty happy. Drove it for 3 days and then no boost, and a terrible sound coming from the turbo area. I inspected the engine, found a busted hose from the airbox to the ICV and also I had made a small mistake when installing the Airbox. I had actually managed to clamp the oil feed line to one of the turbos which resulted in oil starvation to it and it was gone....

http://www.youtube.com/user/farturinn#p/u/0/H612rlMcn0c

Pretty depressing, since its not that easy to access a bottom mount twin turbo system. Still, I bought two new GT2252's and re-designed the oil feed system. Intstalled and I had power again.

I re-designed the oil-feed lines and installed two new Garrett's


The car ran great, power was plenty at 14psi (minimum PSI)

I also installed a new water pump, fan-clutch, oil catch can, Denso Iridium plugs, painted the RC's white, and am currently installing a 2.93 Differential which will get the LSD unit from the S2.65.



Other mods I have done/am doing include the seats which I changed to Recaro Pole Position with some custom stiching and painted the BBS RC wheels white.

Seats:


Sticker:


White RC's


Engine bay, looking OEM as I want it to look. No fancy stuff showing.


Its been a labour of love and some hate, frustration and enjoyment but it has cost me alot of money. At this stage I was happy with the car. I have something a bit special, its fast and reliable and I have rebuilt the engine (top end) myself so that gives me more pleasure when I drive it. But while beeing tuned in the UK the engine blew (on or after the dyno session) and now I need to rebuild the engine.

As I said if you have the time, plese go on my Facebook link http://www.facebook.com/pages/BMW-E3...20153618061202
and hit the like button. You will be doing me a big favor.

Photo Albums
http://myndasafn.bmwkraftur.is/v/med...fart/Rebuild2/
http://myndasafn.bmwkraftur.is/v/med...fart/overhaul/
http://myndasafn.bmwkraftur.is/v/medlimir/fart/GTnew/
http://myndasafn.bmwkraftur.is/v/medlimir/fart/GT_2/
http://myndasafn.bmwkraftur.is/v/medlimir/fart/GT+new/
http://myndasafn.bmwkraftur.is/v/medlimir/fart/GT/

Oh my goodness, you are my HERO!

Cool story bro! And I'm not being sarcastic! That's awesome stuff.

I needs new panties

Thanks for the comments guys

I hope to have something more to report soon, as the engine should come out this weekend and then we will see the extent of the damage.

Wowzers. Quite an ambitious and awesome build.

Wow... I think we should hang out sometime

A small update. A replacement engine block has been bought and also a replacement cylinder head.

We decided to buy a combination of S50B32 engine block and head.

The B32 head has bigger exhaust valves and slimmer valve stems than the B30
The B32 block has a standard bore of 86.4mm compared to the B30's 86mm

The result will be a hybrid of a B30 and B32 Euro motors.

S50B32 cylinder head with the B30GT cams and single vanos from the B30
S50B32 engine blcok with forged 86.5mm B30 pistons, forged JAWS B30 rods and B30 crankshaft creating 3.0L displacement

So a 3.0L S50B32 single vanos..

****ING DROOOOOOOOOOOOOOOL !!!! That is amazingggg !

Pistons have arrived. It's always fun to have new shiny stuff. Big thatnks to Erics Performance Parts on Ebay for their quick and effective service.


CP packaging always impressing


I will forward them to H T Howard and Co in the UK where the replacement block (B32 from B30) will be rebored to 86.5mm (0.1mm overbore). Then its off to Motorworx Marlow for the final assembly

Amazing

Engine build has started!





Comparison of the 2008 Forged CP 8.5:1 pistons and the 2011 version of the same producst



Oil squirters marked from 1-6


Crankshaft is in


Rings gaped and pistons ready for install, just waiting for some new rod bearings

Oh yes, this car... is amazing.

Its running again,



Hopefully on the streets next weekend

oh my god

great work and what a beautiful car

keep it up I know my e36 wishes I loved it as much as you love yours

So the Dyno session is done and I am pretty happy with the results. There were no expectations on massive top end numbers but rather that we had power almost anywhere in the rev-range.



Low boost setup is around 0.75Bar through the revs.
Max HP is 442 and the car is basically at 440hp at 6000rpm
Max Torque is 431ftlbs (580nm) but at below 4000rpm.

Dyno sheet:



High boost setting is climbing to 1.2Bar at max torque, then dropping to about 1.0Bar at the high rpm's. Reason for this is the buildup of backpressure and the turbos run out of breath. Also, the torque had to be limited to below 500ftlbs because the clutch started slipping, even with a clutch that is supposed to be rated 700nm.

Max HP is 488.1hp (or 490) at 6300rpm (rev limiter set at 7200rpm)
Max Torque is limited to 489.4ftlbs but delivered at c.a. 3.700rpm!

At 3000rpm the car is making more power now that it did at the redline when it came out of the factory

Dyno sheet:

yummy!!

and if i read correctly, this latest incarnation is a twin turbo single vanos motor

woo hoo!!


btw, what did you do with the old 'log style' manifolds...




df

Originally Posted by drivinfaster

yummy!!

and if i read correctly, this latest incarnation is a twin turbo single vanos motor

woo hoo!!


btw, what did you do with the old 'log style' manifolds...




df

The Log style manifolds are somewhere in Sweden.

The car was a twin turbo Single vanos beofre but this time around I have full adjustability of the VANOS through the VEMS ECU.

Here is what I would like to know. How can I get those exhaust and intake manifolds. That would make my current project so much easier?

If I have to get them shipped from Germany I dont care just dont even know where to start looking.

Thanks

Originally Posted by MikoPr

Here is what I would like to know. How can I get those exhaust and intake manifolds. That would make my current project so much easier?

If I have to get them shipped from Germany I dont care just dont even know where to start looking.

Thanks

Intake manifold is the Original one, just modified for Turbo

Exhaust manifolds are a custom build, made by JAWS Motorsport in Sweden.

big fan of your car, do you have more close up pics of the turbo manifolds and dump pipe to your exhaust?

Originally Posted by JAM3S

big fan of your car, do you have more close up pics of the turbo manifolds and dump pipe to your exhaust?

here are some

How to spend Christmas and the new year

Got my car back on the 16th of December from it´s 11 month stay in the UK. Unfortunatly upon arrival it was not compleate or at least good enough by my standards, so I deceded to pull the engine out. There were two gaskets missing from the rear turbo which could not be accessed with the engine in.
Also the Crankcase went was not routed the right way and had blown out the valvecover gasket and spilled oil everywhere.

Since the engine came out I decided to paint the engine bay. I started off by fixing some of the damage, sanding down and so on, but did not want to use filler and I don't know how to weld. After the first layer of piant (with a professional gun) I saw that the glossy effect would not really bring out the best of the damages on some of the panels, so I shot 2 coats of flat clear coat.
However, I did not like the flat finish on the struts so I went back to glossy for the struts, which ended of being a semi glossy finish. I kinda like the result, specially after the install of the motor.

Let the fun begin.. December 17th.. My first ever "engine out" operation. Remember that I am not a mechanic Extensive use of Ziplock bags and painters tape to mark everything..








Engine comes out on December 18th. Got some help from a local friend! My 9year old daughter on the camera








Me:


Ready for some treatment...


Since I had access.. why not paint!

This is where the valvecover gasket had blown out of its place due to crankcase pressure.




The reason why the engine came out, missing gasket on the downpipe, also missing a gasket on the exhaust hausing....


Looking forward to the install


Biggest Xmas packet in my house! December 22nd.
Primed:




Painted:








The gun.






3 coats of paint.. looks good but the pictures don´t really catch the imperfections on the fenders.. Custom stickers also in place










Flat finish.. too flat in my opinion..








Finished article, semi glossy struts, with Flat/matte finish on the rest. I raelly like it.

Motor back in place on the 26th


Face back on the car, waiting for a new front windshield.


VEMS in place and the MAP sensor hose going through the lid, so I can now close it properly


Catch can fastined, and the vent now routed into the air intake pipe, before the front turbo and after the KN cone.




I also used the opertunity since painting to cut a bit from the inside fender to be able to fit 3" intercooler piping.


Also installed a Z3 shifter which is a great addition! Amazing feel.



Flushed the brake system and put a new batch of ATE super blue racing fluid, also change the oil to the Castrol M-approved 10W-60



I also had a broken front windshield so I had that replaced on the 29th.










My assistants in the garage.




Supersprint exhaust installed, this is a new upgrade.