avalaugh Posted October 1, 2017 Report Share Posted October 1, 2017 Well it's official, my Super Charger has been sold on and I'm going Turbo. For anyone wanting background on the car here is the build. Super Charging build thread. https://r.tapatalk.com/shareLink?share_fid=37151&share_tid=62290&url=http://www.e46zone.com/forum/index.php?/topic/62290-Super-Charging-build-thread%2E&share_type=t It was a great set up and served me well, but the hunt for more power has led me here, 3x pistons with broken ring lands Sent from my iPhone using Tapatalk govich and momo 2 Quote Link to comment Share on other sites More sharing options...
momo Posted October 1, 2017 Report Share Posted October 1, 2017 Link fixed! Looking forward to the progress.. avalaugh 1 Quote Link to comment Share on other sites More sharing options...
avalaugh Posted October 1, 2017 Author Report Share Posted October 1, 2017 This will be a bare block build, consisting of FORGED rods and pistons.After doing some research on various turbo's, and finding something that's suitable and doesn't cost a ridiculous amount I've chosen to go with a HOLSET HX35 twin scroll, There's no doubt the HX35 is the most common and popular Holset in the tuning scene, and the 12cm turbine version is famously popular, but for larger engines, especially 3ltr+, but smaller engines too if you want the maximum power for your psi, a slightly larger 16cm housing is needed.On 3ltr and larger engines (and rotaries), running a smaller 12cm housing will gain you nothing in spool, in fact it may be that restrictive it would spool slower than this larger 16cm housing, and of course it will give much less power and much higher pre-turbine backpressure which is bad for reliability too- Overly small turbines on larger engines is one of the biggest mistakes people make in tuning!This particular HX35 is a very late spec version, signified by the very large Holset logo and TVS on the compressor housing. This one also has a very interesting late design compressor too, slightly smaller in overall diameter to earlier ones at 76mm for improved response, but the sought after high flow 7 blade design rather than the more common 8 blade, so still capable of 550bhp or more when pushed hard.I've got lots more in the pipeline but will update as things progress, I'm especially excited about the custom manifold I'm having made, a true twin scroll with 3 cylinders per scroll and twin wastegate [emoji12]Sent from my iPhone using Tapatalk Markus5000, momo, R11CH and 1 other 4 Quote Link to comment Share on other sites More sharing options...
Tazman861 Posted October 2, 2017 Report Share Posted October 2, 2017 I shall look forward to your progress did you consider a N54 set up or is that a red herring route?Sent from my iPhone using Tapatalk Quote Link to comment Share on other sites More sharing options...
avalaugh Posted October 2, 2017 Author Report Share Posted October 2, 2017 Not worth it mate. Unless you were to buy the car and ditch the E46. It's based on the M54, but doesn't have a closed deck block, and then once you factor in the need for switching ECU's or going standalone. Plus the cost of buying the N54, dumping the twin turbo's and going for a single etc etc Yes it's a red herring [emoji23][emoji23] Sent from my iPhone using Tapatalk Quote Link to comment Share on other sites More sharing options...
avalaugh Posted October 2, 2017 Author Report Share Posted October 2, 2017 You know it's gonna be a filthy dirty ride when you can give it a good fisting before it's even turned on......Sent from my iPhone using Tapatalk TriggerFish 1 Quote Link to comment Share on other sites More sharing options...
R11CH Posted October 3, 2017 Report Share Posted October 3, 2017 Pure filth ! Manage to sell the charger then, Wish i could have afforded it, since driving yours i need boost!! avalaugh 1 Quote Link to comment Share on other sites More sharing options...
avalaugh Posted October 8, 2017 Author Report Share Posted October 8, 2017 Got stuck in to the cylinder head this week, it's looking a million times better now.And after many hours hunched over in my garage.....Sent from my iPhone using Tapatalk TriggerFish, Markxr, ibrahimx2001 and 1 other 4 Quote Link to comment Share on other sites More sharing options...
avalaugh Posted October 19, 2017 Author Report Share Posted October 19, 2017 Heads all done, valves have also been ground and angled, exhaust seat has been widened to aid cooling too.All now reassembled with SUPERTECH VITON valve stem oil seals [emoji106]Not much else on progress so far, but the manifold is starting to take shape.Sent from my iPhone using Tapatalk Markxr, R11CH and momo 3 Quote Link to comment Share on other sites More sharing options...
Markxr Posted October 20, 2017 Report Share Posted October 20, 2017 Manifold looks good Quote Link to comment Share on other sites More sharing options...
govich Posted October 21, 2017 Report Share Posted October 21, 2017 I like where this is going... Definitely need to sort the CCV out now! Quote Link to comment Share on other sites More sharing options...
2clubsp Posted October 23, 2017 Report Share Posted October 23, 2017 (edited) On 19/10/2017 at 21:07, avalaugh said: Not much else on progress so far, but the manifold is starting to take shape. Sent from my iPhone using Tapatalk Is equal length header pipes not a consideration? Genuine question. Edited October 23, 2017 by 2clubsp Quote Link to comment Share on other sites More sharing options...
avalaugh Posted October 25, 2017 Author Report Share Posted October 25, 2017 To be honest, the space available isn’t really enough for equal length headers, yes there would be a small benefit to having them though.The manifold is coming along wellNow it’s time for the wastegate pipework, that’s 2 runs, 1 from each bank of 3 cylinders to 2x wastegates, then from those 2 more pipe runs linking back into the 3” exhaust which also has to clear the steering column [emoji15]Going to look a bit crazy I think.Sent from my iPhone using Tapatalk Markxr 1 Quote Link to comment Share on other sites More sharing options...
avalaugh Posted October 25, 2017 Author Report Share Posted October 25, 2017 Yes there is advantages to equal length headers, but the space available is very tight.Manifold is coming along wellNow it’s time to cut into each bank of 3 for 2x wastegates, then from both wastegates 2x pipes going into the 3” downpipe, and all this also has to avoid the steering column and engine mount. It’s really very very tight.Sent from my iPhone using Tapatalk Markxr 1 Quote Link to comment Share on other sites More sharing options...
avalaugh Posted October 27, 2017 Author Report Share Posted October 27, 2017 Rods have arrived today, look much stronger than the stock items And for all the keyboard warriors out there that say the stock rods are forged, I can assure you they are not. A forged rod rings like a bell, take a look at this video R11CH 1 Quote Link to comment Share on other sites More sharing options...
Benji83 Posted November 18, 2017 Report Share Posted November 18, 2017 Almost forgot about this, I never knew that about con rods! The manifold is looking nice, I can't wait to see you get it all fitted in. I'm guessing you're going to keep the bonnet the same or is an M3 style one possibly necessary for intake pipe room over the top of the engine? Quote Link to comment Share on other sites More sharing options...
avalaugh Posted November 19, 2017 Author Report Share Posted November 19, 2017 Keeping original Bonnet, no pipework going over the top of engine either.Unfortunately progress has been slow, the manifold has been scrapped and started over again for various reasons.I’m still waiting on the WISECO pistons also, so no engine assembly has started.I have made the most of this time by cleaning, everything.Sent from my iPhone using Tapatalk R11CH 1 Quote Link to comment Share on other sites More sharing options...
avalaugh Posted November 19, 2017 Author Report Share Posted November 19, 2017 I’ve had a AN10 fitting welded into the timing my case cover for turbo oil drainSent from my iPhone using Tapatalk R11CH 1 Quote Link to comment Share on other sites More sharing options...
avalaugh Posted November 19, 2017 Author Report Share Posted November 19, 2017 And since there’s going to be such a huge power increase, I’ve also taken the time to add some proper brakes, now running 6 pots up front and 4 pots at the rear.Discs all round are 32mm thick 335mm diameter.Sent from my iPhone using Tapatalk R11CH, TriggerFish and Markxr 3 Quote Link to comment Share on other sites More sharing options...
TriggerFish Posted November 20, 2017 Report Share Posted November 20, 2017 Awesome stuff! Are you making the manifolds yourself? Quote Link to comment Share on other sites More sharing options...
avalaugh Posted November 21, 2017 Author Report Share Posted November 21, 2017 Awesome stuff! Are you making the manifolds yourself? No mate, wish I could but myvwelding skills are pretty poop.Sent from my iPhone using Tapatalk Quote Link to comment Share on other sites More sharing options...
avalaugh Posted November 22, 2017 Author Report Share Posted November 22, 2017 Parts are starting to arrive now, so getting excited again, got down to my mates workshop today and done some work to the block. Drilled out the block and tapped some M12 threads in using a flute tap which forms the threads rather than cutting them, makes for a stronger fixing once the steel TIMESERTS are installed and the RACEWEAR headstuds go in. [emoji106][emoji108] Excuse the drill bit getting stuck, typical it only happed on the only hole I filmed lol https://youtu.be/oYmRH6ouEHw Sent from my iPhone using Tapatalk TamHam79 and R11CH 2 Quote Link to comment Share on other sites More sharing options...
R11CH Posted November 23, 2017 Report Share Posted November 23, 2017 Good stuff Paul. Up and running by next week then yeah haha. So whats your power goal then ? Quote Link to comment Share on other sites More sharing options...
avalaugh Posted November 24, 2017 Author Report Share Posted November 24, 2017 550bhp will be a very conservative tune, the engine will be capable of ALOT more, 8-900bhp but that sort of power comes with a complete new set of challenges, chassis and driveline wise.So it’s my fuel system which is my limiting factor as want to keep it stockish, just uprated pump and injectors.Looking for a super power band though, from 3600-7000rpm should see a nice flat torque curve [emoji108][emoji106]Pistons arrived yesterdaySo whizzed everything down to the machine shop, they are over sized so block needs boring, crank is being polished, head and blocked skimmed too.Sent from my iPhone using Tapatalk Quote Link to comment Share on other sites More sharing options...
avalaugh Posted November 24, 2017 Author Report Share Posted November 24, 2017 These WISECO pistons are just a giant improvement from the stock ones.Oil ring must be 3 times as big tooSent from my iPhone using Tapatalk Markxr 1 Quote Link to comment Share on other sites More sharing options...