M30 Turbo update thread ****RUNNING

[glenn]

One day on topgear i saw Clarkson mentioning some valve in exhaust that opens when you press throttle hard, something like this is uset in aston martins. They say that when it's closed the car is normally quiet, but when it opens you can hear the roar even 2 miles away

BMW 330i backbox has this valve

most big superbikes have got exhaust valves,
they alter the power/torque characteristics.

[Batch]

Interesting. Maybe someone can help me find some pics of it?

[weegaz22]

Interesting. Maybe someone can help me find some pics of it?

for a motorbike version have a google search for EXUP valve, its used on most 4 cyl yamahas, helps improve mid range torque as 4cyl bike engines are revving to 14k to make their power so they can be a little gutless lower down the range

[lentec]

HTH

Also see http://www.usgear.com/alert.htm

[Batch]

Tnx a lot

[bigkev]

bike valves are normally placed at the collector in the exhaust effectively turning it from a 4-2-1 at low revs into a 4-1 at high revs if i remember correctly the 330i has it at the tailpipe not sure if this is for performance or just sound

[Toby_Unna]

Erm anyway, back on topic

little progress due to weather and lack of money, but a few more things sorted now...



finally got both turbo flanges. inlet was dead easy Ԛ£12 job through work, but i couldn't find a 6 bolt t4 outlet anywhere so had to buy a 4-bolt one from the states ($25 shipped) and re-drill it to the right pattern







IC all mounted properly and valance back on, cool-side plumbing in place

Spal fan installed and fits between rad and IC without touching either (thank fcuk!)





megasquirt half built but not ready to do any squirting just yet



various Ford and Bosch variable throttle position sensors. all use a different resistance range when tester on the meter so not sure which is best



finally, bought a complete RS Turbo stainless exhaust from ebay for Ԛ£60 lots of decent bends to make a down pipe from and a small single box with an 11 inch tailpipe which will need removing. it's all 2.5 inch which might be too small, but i'm going to try it. the turbine exit is 2.5 inch.

[Ant]

the TPS resistance is nothing to worry about Toby, the MS ECU takes and uses the raw value for it as ADC counts not VR so no real issue there M8, M50 unit easiest to fit but any D drive type will do, Volvo 850TPS seems popular in the US

getting there with your MS then dude ! Stim is a must have for sure, 9V dont last long though, I use a small M/cycle battery and some flying leads, lasts a day almost on one charge

Pipe looks good to ! bargain

[Andy335Touring]

Nice one mate , whats the next job on the to do list ?

[Jon_Bmw]

Making good progress by the looks of it. Its strange seeing the throttle body on that side of the inlet. What is the inlet track like now after the throttle body because presumably previously the air was guided into the different ports but perhaps not now?? If you can understand where i'm coming from there.

Exhaust looks good on reflection i think 2.5 inch probably will be big enough, as you said bin that drainpipe wrongness tailpipe. Do you know of any exhaust places(i don't mean kwik fit or the like) near you as if you do you can usually go in wave some cash at them they can make you any bends you want in whatever size for little money.

Its taking shape now, can't wait to see further progress, did you sort out what you are going to be doing for oil feed/return lines?

Jon

[glenn]

awesome work toby,
i dont envy you with the megasquit mate, just reading the various posts about it, confuses me
exhaust tubing looks good too, i think 2.5" will be fine.

[e30_Turbo]

Looking good Toby!

I remember my garage full of parts, collecting them seemed to go on forever! Felt so good putting them to use

Would you think that the fan would fit a std m20 rad?

And any MS questions I am always here to help (all that is).

And on another note, I'm now on the hunt for a 3.25 lsd, any ideas?

Mark

[DieselMeister]

Sweet

Nice work matey.

[Toby_Unna]

CRITICAL DEVELOPMENT

just bought a shitty diesel 205 off ebay to use instead of the m535, which should do at least twice the mpg and will give me an instant Ԛ£140 insurance refund.

cost 185 admittedly but that's with 7.5 months tax which will refund over 100 if claimed back (if it breaks )

more money for the 335i

Jon, Alpina/Hartge or someone used a similar design so i'm not worried about the inlet

Mark, the fan should fit anything. it's under 7cm thin and 13" diameter. could weld up mounts easy if required using mine as a pattern. it's a Spal, can find u the model number if u need. I think 3.25 is a good diff ratio too, that's what i'm going with to begin.

[jonmsm]

whats happening to the 535 now then if your using the pug? I knwo the feeeling thought, the merc is proving such a good cheap alternative to running an m535i as a daily car!

Hows the audi article coming on and do you still need the quattro we have as its back in one piece and fully ready to go!

Jon

[Toby_Unna]

Well it might be 4.40 in the morning but...









...MY MEGASQUIRT WORKS!!

mmm bed now i think..

Also inlet manifold fitted with 30lb injectors from the states (used 130$ delivered, may still be too small )
and tarted up a bit - at least one thing in the bay will look half decent!







looks nice innit!

best of all, the nasty 205 diesel is doing 50mpg which is saving me a fortune over 18mpg in the m535i

[Turbo-Brown]

Sweeeet!

Can't wait to see your's finished Toby!

Looks like you're gonna beat me back onto the road at this rate!

[Ritchie]

Looks great Toby, im following your progress with great interest.

[Toby_Unna]

now finished

[DieselMeister]

Nice work.

Now get it all rolling and throw up some vids

[redrobbie]

You guys amaze me, the stuff you can do.

[Toby_Unna]

Inlet manifold finished apart from throttle bracket, and installed

exhaust not so straightforward unfortunately, turbo is a bit bloody big

Mr Turbo Brown, you have pm...

[Kos]

Inlet manifold finished apart from throttle bracket, and installed

exhaust not so straightforward unfortunately, turbo is a bit bloody big

Mr Turbo Brown, you have pm...

exactly what i'm doing to my inlet manifold, but ,may be using a late 535i TB, a "fly by wire" throttle depending on management

[Andy335Touring]

Keep at it dude as it's going to be a beast of a car !

[Turbo-Brown]

Bloody hell, that turbo is a beast!

Think I've replied to your PM Toby, it told me that it had failed though so I tried again so you might end up with two copies.

Hope it's of some help!

[Toby_Unna]

back to the drawing board...

making a log exhaust manifold now. having flanges made by someone or other, short round stubs, and log bbody fab'd from 5mm sheet steel and seam welded...













please tell me what you think of the turbo position as i can move it. needs to be far forward for plug access and so comp doesn't get too near mani body. and yes i know the downpipe routing is going to be fun!

[Ant]

perfection I'd say M8

[Toby_Unna]

That piece of tubing is ideal for the stubs isn't it, didn't cost a penny

the manifold body design isn't perfect, but with the turbo flange in the right place it can be whatever shape is easiest.

wastegate fits really nicely too, mounted upside down underneath the manifold at the front (underneath turbo), with outlet facing backwards to merge with downpipe.

[Turbo-Brown]

Looks like bags of room for the downpipe in the piccies, can run it round the outside of the steering column if needs be?

Definately an idea to lose the rubber donut if you do though!

[Toby_Unna]

It will fit one way or the other! might have to put a little dent in the manifold but it won't be a problem don't think there's room on the far side of the column though.

main thing is getting these flanges sorted, finding some steel and buying a lot of cutting discs for the grinder!

[bigkev]

dont know if that wooden manifold cover will take the heat toby
might have to treat it with something

[Toby_Unna]

Ronseal should help

although i reckon wood will be fine

it's good quality pine u know

[glenn]

your turbo position looks to be the most practical that's available toby.
you can always spin the comp snail if you cant sort out tubing for it as it is.

[Toby_Unna]

agree with that Glenn. might just be a bit far forward, but i think i can put a rubber bend on the inlet and a big filter where the brake duct goes

[Ant]

I'll try and find my downpipe pix Toby, I had to hug the block and gearbox to clear the steering so they may provide some inspiration.

if you clock the snail so the comp outlet sits in the 6.30 position that merc charge pipe will be perfecto just need a hard section added to carry it forwards to the IC

Dammit, why aren't you more local, I'd be out there now with ya M8