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    • DCT Build Part XII - Build complete, pictures of final assembly, transmission cooler, and Viton seals

      Well, this has been a rather lengthy road to completion but the transmission is basically complete. The car was dropped off by SSP last month to Gintani who should have the motor in by the end of this week. The problem is SSP mounted their trans cooler in the location the heat exchanger for the supercharger needs to go so SSP will need to come to Gintani's facility to re-run their lines as the cooler will need to go in a different location. What took so long for this update? Well, we have been waiting, and waiting, and waiting for SSP to send us details on the Viton seals that required 3 redesigns but never received the information on why these seals are superior to the stock units.

      So, I decided to do my own research and here is what I came up with. These are the stock BMW seals used in the DCT. What is wrong with them exactly? We do not know other than they apparently are not up to the task:










      Here are the Viton seals which delayed the project by 3 months. Viton is a synthetic rubber used for seals, O-rings, things of that sort. Viton was likely used as it is less susceptible to decay and already used in BMW applications such as in VANOS. Viton has much higher temperature and chemical resistance characteristics than the stock seals. Here is what they look like:










      This is the DCT cooler that was mounted by SSP up front. This needs to be moved somewhere else as the supercharger heat exchanger will need to go there. This means SSP will need to come out and run their lines again checking all their fluids and so forth before tuning can take place:














      This is the final assembly. So, the transmission is built but it took about a year longer than estimated. I believe I was as patient as possible and hopefully this will all be wrapped up in December with a built motor, built transmission, a YSI, and a ton of horsepower.





































      This article was originally published in forum thread: M3 DCT Build Journal - World's First BMW DCT Build started by Sticky View original post
      Comments 2372 Comments
      1. benzy89's Avatar
        benzy89 -
        Click here to enlarge Originally Posted by klipseracer Click here to enlarge
        Wouldn't this create issues with the rings when it crosses from the stock cylinder walls onto the spacer? Or would the gap between the top of the piston and the rings not require the rings to cross this threshold?
        Elongated sleeves will compensate for the "spacer", so the pistons + rings will never travel across a disruption
      1. DFM's Avatar
        DFM -
        Click here to enlarge Originally Posted by JRCART Click here to enlarge
        Sticky, you keep hiding behind the DCT excuse, GT-R's have a more complext DCT than your car and people have been building GT-R for years. Audi R8's have a DCT and tuners have been building some sick R8s for years. $#@!ing NASA put a man on the moon in less time than this build took....and a DCT is not rocket sciene.
        As of the 2013 model they do...
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by klipseracer Click here to enlarge
        sorry sticky, but this was funny.
        Laugh at whatever you want to man.
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by benzy89 Click here to enlarge
        Elongated sleeves will compensate for the "spacer", so the pistons + rings will never travel across a disruption
        Smart man.
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by DFM Click here to enlarge
        As of the 2013 model they do...
        Thank you, they just got it and these haven't even hit showrooms.
      1. DavidV's Avatar
        DavidV -
        Click here to enlarge Originally Posted by Sticky Click here to enlarge
        It's fine man, the feeling is mutual. It's a long list of people, trust me.
        Ok, I'm back to feeling for you for the missing of your car..
        I can see raising the deck highth of the block having all sort of delaying implications.
        I'll be try to be more patient...again.
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by DavidV Click here to enlarge
        Ok, I'm back to feeling for you for the missing of your car..
        I can see raising the deck highth of the block having all sort of delaying implications.
        I'll be try to be more patient...again.
        I haven't said what was done really. I'll go into it all eventually, I promise. I'm not the kind of guy not to.
      1. klipseracer's Avatar
        klipseracer -
        Click here to enlarge Originally Posted by DFM Click here to enlarge
        As of the 2013 model they do...
        But I thought you mentioned that it wouldn't be necessary to 'sleeve' the block? So I had assumed this would be done without any sleeving work.
      1. benzy89's Avatar
        benzy89 -
        Click here to enlarge Originally Posted by klipseracer Click here to enlarge
        But I thought you mentioned that it wouldn't be necessary to 'sleeve' the block? So I had assumed this would be done without any sleeving work.
        I'm gonna assume you meant to quote me since I previously quoted you about the sleeves being elongated to pass through the spacer. All Gintani Stage 3 builds get sleeved blocks. The problem is that when you strap a Vortech YSI blower on, the S65 alusil block has flex issues. The iron spacer is there to give the block additional rigidity (and in turn, fight off the block flex).
      1. klipseracer's Avatar
        klipseracer -
        Click here to enlarge Originally Posted by benzy89 Click here to enlarge
        I'm gonna assume you meant to quote me since I previously quoted you about the sleeves being elongated to pass through the spacer. All Gintani Stage 3 builds get sleeved blocks. The problem is that when you strap a Vortech YSI blower on, the S65 alusil block has flex issues. The iron spacer is there to give the block additional rigidity (and in turn, fight off the block flex).
        No I meant to quote sticky as it was his comment I was referencing. But I recalled wrong, he said he wasn't going to do flanged sleeves. Thats where my confusion came from as I thought he said no sleeves period.
      1. JRCART's Avatar
        JRCART -
        Sticky claims he is running the Sunday Shift Sector event in 4 weeks.....Click here to enlarge
      1. Sticky's Avatar
        Sticky -
        I intend to be there, we'll see.
      1. klipseracer's Avatar
        klipseracer -
        Click here to enlarge Originally Posted by Sticky Click here to enlarge
        I intend to be there, we'll see.
        Tuning alone will eat up a good portion of these 4 weeks with unpaved territory, no?
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by klipseracer Click here to enlarge
        Tuning alone will eat up a good portion of these 4 weeks with unpaved territory, no?
        No.
      1. klipseracer's Avatar
        klipseracer -
        Click here to enlarge Originally Posted by Sticky Click here to enlarge
        No.
        Mkay. Have they made the sleeves/rods yet?
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by klipseracer Click here to enlarge
        Mkay. Have they made the sleeves/rods yet?
        Yes.
      1. Sticky's Avatar
        Sticky -
        Good news, car should be started this week. There's going to be hell to pay.
      1. klipseracer's Avatar
        klipseracer -
        Click here to enlarge Originally Posted by Sticky Click here to enlarge
        Good news, car should be started this week. There's going to be hell to pay.
        Well that explains a little bit! Hope to have a start up video? Click here to enlarge
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by klipseracer Click here to enlarge
        Well that explains a little bit! Hope to have a start up video? Click here to enlarge
        I'll get you one as soon as they start it.
      1. klipseracer's Avatar
        klipseracer -
        Click here to enlarge Originally Posted by Sticky Click here to enlarge
        I'll get you one as soon as they start it.
        Awesome. Hopefully they took some pics of the new long rod setup?