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avalaugh

Turbo Charged build thread...

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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

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This will be a bare block build, consisting of FORGED rods and pistons.

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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.

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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]


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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]

 

 

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Pure filth !

Manage to sell the charger then, Wish i could have afforded it, since driving yours i need boost!!

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Heads all done, valves have also been ground and angled, exhaust seat has been widened to aid cooling too.

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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.

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On 19/10/2017 at 21:07, avalaugh said:

Not much else on progress so far, but the manifold is starting to take shape.

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Is equal length header pipes not a consideration? Genuine question.

Edited by 2clubsp

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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 well
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Now 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.


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Yes there is advantages to equal length headers, but the space available is very tight.

Manifold is coming along well
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Now 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.


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Rods have arrived today, look much stronger than the stock items

 

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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

 

 

 

 

 

 

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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?

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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.

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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.

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Awesome stuff! Are you making the manifolds yourself? 

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Awesome stuff! Are you making the manifolds yourself? 


No mate, wish I could but myvwelding skills are pretty poop.


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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

 

 

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Good stuff Paul. Up and running by next week then yeah haha.

So whats your power goal then ? 

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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 yesterday

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So whizzed everything down to the machine shop, they are over sized so block needs boring, crank is being polished, head and blocked skimmed too.


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These WISECO pistons are just a giant improvement from the stock ones.

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Oil ring must be 3 times as big too


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