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  1. #1
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    Custom tuning/pulley options.

    I recently opted for the ESS 625 kit. Originally Andrew (owner of AR Design/Alpha Motorsports here in Colorado) and myself were going to swap pulleys and re-tune the car to make up for the harsh elevation hit in power. We are running into an issue here though with the pulley/tune situation. We spoke with ESS and they are not willing to give any info on pulleys or offer a different tune to compensate for an aftermarket pulley/elevation. We ordered a vortech pulley, but noticed ESS machines a damn offset into the 625 pulley supplied. So my questions are:

    1. For those who swap pulleys, how do you go about doing so since ESS machines an offset into their pulleys in the kits?

    2. My car made 526hp SAE (mid 400's uncorrected i think) so what would be a "SAFE" number to shoot for up here in Colorado? I figure if I can get her to an actual 500-520 UNCORRECTED (which would show 600+ corrected up here) would be nice up here in this horridly thin Colorado air.

    3. TUNING..... My biggest issue. Are there any vendors that offer custom tunes for these cars, or any stand alone routes (EMS/Motec/ProEFI) that are available to us? Is it possible to switch over to E85? If so, what fuel components need to be upgraded?

    Sorry if these are noob questions. My previous cars/bikes were not locked down like this damn M3 is, and tuning is such a freaking issue with this car. Thanks
    -08 E92 Brushed Steel DCT 613hp-
    -ESS/AR 700 - KW V3's - AR Design - Volk TE37 - Vorsteiner - Challenge-
    -2012 Brushed Red Aluminum GTR-
    - Jacks 3.8 w/ Jacks heads - Jacks Drag 800 w/ billet gears - AAM GT-900R - Swift - ADV.1 - Ecutek via Visconti -
    - 1060hp 852tq 32psi - 9.34 @150mph 7688ft DA - 185.5mph 1/2 mile 9240ft DA -
    http://www.jackstransmissions.com/
    http://store.vtune.us/
    http://www.revvolution.com/

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    Click here to enlarge Originally Posted by BlownE92M3 Click here to enlarge
    1. For those who swap pulleys, how do you go about doing so since ESS machines an offset into their pulleys in the kits

    this is false- the fastest ESS car owners/VT3 built motor guys, have stated very clearly, vortech pulleys will fit- As I was told, only my singular UK version pulley had an offset to it, the rest will work



    2. My car made 526hp SAE (mid 400's uncorrected i think) so what would be a "SAFE" number to shoot for up here in Colorado? I figure if I can get her to an actual 500-520 UNCORRECTED (which would show 600+ corrected up here) would be nice up here in this horridly thin Colorado air.
    not much more, maybe 560,

    3. TUNING..... My biggest issue. Are there any vendors that offer custom tunes for these cars, or any stand alone routes (EMS/Motec/ProEFI) that are available to us? Is it possible to switch over to E85? If so, what fuel components need to be upgraded?

    Pro-EFI has a solution for stand-alones. you would be goin into uncharted territory on your own. I dont think anyone is ready to tune on top of already dangerous tuning due to fallout down the road.
    with that said, you should be ok to add another psi or so w/o issue, but would need to see/log everything


    bold @BrenM3 might have some insight though

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    Click here to enlarge Originally Posted by BlownE92M3 Click here to enlarge
    So my questions are:
    i knew i heard this convo before:
    http://bimmerboost.com/showthread.ph...205#post319205

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    I feel your pain OP. Moved from the West Coast to Denver and truly felt the power loss as soon as the car got off the transport.

    Good luck on your quest.

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    You need boost. But ess offers canned tunes so you need a tuner to accommodate you.

    Stage 2 or 2.5 E9X M3 S65 V8 supercharger kit for sale
    : http://www.boostaddict.com/showthrea...r-kit-for-sale

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    Click here to enlarge Originally Posted by LostMarine Click here to enlarge
    Hrmm i saw he swapped pulley, but how did he add fuel? Will the ECU auto compensate with the added boost automatically or will i need to find out a way to tune for more air?

    Click here to enlarge Originally Posted by Sticky Click here to enlarge
    You need boost. But ess offers canned tunes so you need a tuner to accommodate you.
    EXACTLY! Tuning is my biggest issue. I Already have the pulley, just need to make sure im safe with fuel.
    -08 E92 Brushed Steel DCT 613hp-
    -ESS/AR 700 - KW V3's - AR Design - Volk TE37 - Vorsteiner - Challenge-
    -2012 Brushed Red Aluminum GTR-
    - Jacks 3.8 w/ Jacks heads - Jacks Drag 800 w/ billet gears - AAM GT-900R - Swift - ADV.1 - Ecutek via Visconti -
    - 1060hp 852tq 32psi - 9.34 @150mph 7688ft DA - 185.5mph 1/2 mile 9240ft DA -
    http://www.jackstransmissions.com/
    http://store.vtune.us/
    http://www.revvolution.com/

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    go to a dyno and check out everything with the new setup you want to try out.
    F10 M5 : ??????
    E90 M3: 11.2 126.7 with a 1.8 60ft Street Tires, Stock Interior,DSC on

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    Click here to enlarge Originally Posted by BlownE92M3 Click here to enlarge
    Hrmm i saw he swapped pulley, but how did he add fuel? Will the ECU auto compensate with the added boost automatically or will i need to find out a way to tune for more air?



    EXACTLY! Tuning is my biggest issue. I Already have the pulley, just need to make sure im safe with fuel.
    @M&M has his own tuning, so you would need to talk to him i tagged @BrenM3 as well because he does tuning also, but not sure what has/willing to do

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    Bump for @BrenM3 or @M&M
    -08 E92 Brushed Steel DCT 613hp-
    -ESS/AR 700 - KW V3's - AR Design - Volk TE37 - Vorsteiner - Challenge-
    -2012 Brushed Red Aluminum GTR-
    - Jacks 3.8 w/ Jacks heads - Jacks Drag 800 w/ billet gears - AAM GT-900R - Swift - ADV.1 - Ecutek via Visconti -
    - 1060hp 852tq 32psi - 9.34 @150mph 7688ft DA - 185.5mph 1/2 mile 9240ft DA -
    http://www.jackstransmissions.com/
    http://store.vtune.us/
    http://www.revvolution.com/

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    Click here to enlarge Originally Posted by BlownE92M3 Click here to enlarge
    Bump for @BrenM3 or @M&M
    what pulley do you have on and awaiting install?

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    Click here to enlarge Originally Posted by LostMarine Click here to enlarge
    what pulley do you have on and awaiting install?
    I have the standard ESS 625 pulley on the car, and a 3.8" (96.5mm) sitting at shop
    -08 E92 Brushed Steel DCT 613hp-
    -ESS/AR 700 - KW V3's - AR Design - Volk TE37 - Vorsteiner - Challenge-
    -2012 Brushed Red Aluminum GTR-
    - Jacks 3.8 w/ Jacks heads - Jacks Drag 800 w/ billet gears - AAM GT-900R - Swift - ADV.1 - Ecutek via Visconti -
    - 1060hp 852tq 32psi - 9.34 @150mph 7688ft DA - 185.5mph 1/2 mile 9240ft DA -
    http://www.jackstransmissions.com/
    http://store.vtune.us/
    http://www.revvolution.com/

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    Click here to enlarge Originally Posted by BlownE92M3 Click here to enlarge
    I have the standard ESS 625 pulley on the car, and a 3.8" (96.5mm) sitting at shop
    Correction, a 3.6" (91.4mm) is sitting at AR Design.
    -08 E92 Brushed Steel DCT 613hp-
    -ESS/AR 700 - KW V3's - AR Design - Volk TE37 - Vorsteiner - Challenge-
    -2012 Brushed Red Aluminum GTR-
    - Jacks 3.8 w/ Jacks heads - Jacks Drag 800 w/ billet gears - AAM GT-900R - Swift - ADV.1 - Ecutek via Visconti -
    - 1060hp 852tq 32psi - 9.34 @150mph 7688ft DA - 185.5mph 1/2 mile 9240ft DA -
    http://www.jackstransmissions.com/
    http://store.vtune.us/
    http://www.revvolution.com/

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    Click here to enlarge Originally Posted by BlownE92M3 Click here to enlarge
    Correction, a 3.6" (91.4mm) is sitting at AR Design.

    I think you'll be fine with that. thats probably the "92mm" pulley they sold with the actual 625 kits for years. its a 5 minute swap, so schedule the dyno, do a few pulls, swap pully, do a few more to check AFR, you should be ok

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    Click here to enlarge Originally Posted by LostMarine Click here to enlarge
    I think you'll be fine with that. thats probably the "92mm" pulley they sold with the actual 625 kits for years. its a 5 minute swap, so schedule the dyno, do a few pulls, swap pully, do a few more to check AFR, you should be ok
    Hmm Gotcha. Will try tomorrow then.
    -08 E92 Brushed Steel DCT 613hp-
    -ESS/AR 700 - KW V3's - AR Design - Volk TE37 - Vorsteiner - Challenge-
    -2012 Brushed Red Aluminum GTR-
    - Jacks 3.8 w/ Jacks heads - Jacks Drag 800 w/ billet gears - AAM GT-900R - Swift - ADV.1 - Ecutek via Visconti -
    - 1060hp 852tq 32psi - 9.34 @150mph 7688ft DA - 185.5mph 1/2 mile 9240ft DA -
    http://www.jackstransmissions.com/
    http://store.vtune.us/
    http://www.revvolution.com/

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    Click here to enlarge Originally Posted by LostMarine Click here to enlarge
    I think you'll be fine with that. thats probably the "92mm" pulley they sold with the actual 625 kits for years. its a 5 minute swap, so schedule the dyno, do a few pulls, swap pully, do a few more to check AFR, you should be ok
    Will the ECU auto-compensate and add more fuel if for the 1-2psi extra we will be pushing?
    -08 E92 Brushed Steel DCT 613hp-
    -ESS/AR 700 - KW V3's - AR Design - Volk TE37 - Vorsteiner - Challenge-
    -2012 Brushed Red Aluminum GTR-
    - Jacks 3.8 w/ Jacks heads - Jacks Drag 800 w/ billet gears - AAM GT-900R - Swift - ADV.1 - Ecutek via Visconti -
    - 1060hp 852tq 32psi - 9.34 @150mph 7688ft DA - 185.5mph 1/2 mile 9240ft DA -
    http://www.jackstransmissions.com/
    http://store.vtune.us/
    http://www.revvolution.com/

  16. #16
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    Click here to enlarge Originally Posted by BlownE92M3 Click here to enlarge
    Will the ECU auto-compensate and add more fuel if for the 1-2psi extra we will be pushing?
    i doubt it, but you should be tuned for "x" boost anyway. this is why i said do it on the dyno. your probably running rich as its sits now.

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    Not trying to open up any cans of worms, but have you considered contacting @evolve since they have custom tuned a few BMWs in CO. One of them being an E46 M3 with a ESS VT2-500 owned by @normcaldwell.
    2002 E46 M3 6MT | Jet Black . Black Nappa | My GermanBoost Build Thread
    2009 E90 M3 DCT | Melbourne Red . Speed Cloth

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    Click here to enlarge Originally Posted by flipm3 Click here to enlarge
    Not trying to open up any cans of worms, but have you considered contacting @evolve since they have custom tuned a few BMWs in CO. One of them being an E46 M3 with a ESS VT2-500 owned by @normcaldwell .
    I thought they didn't/couldn't custom tune????
    -08 E92 Brushed Steel DCT 613hp-
    -ESS/AR 700 - KW V3's - AR Design - Volk TE37 - Vorsteiner - Challenge-
    -2012 Brushed Red Aluminum GTR-
    - Jacks 3.8 w/ Jacks heads - Jacks Drag 800 w/ billet gears - AAM GT-900R - Swift - ADV.1 - Ecutek via Visconti -
    - 1060hp 852tq 32psi - 9.34 @150mph 7688ft DA - 185.5mph 1/2 mile 9240ft DA -
    http://www.jackstransmissions.com/
    http://store.vtune.us/
    http://www.revvolution.com/

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    1 out of 1 members liked this post. Yes Reputation No
    Are you sure ESS does not machine away some of the pulley? You should put the pulleys side by side, on a flat surface, with the face of the pulley that rests on the blower shaft down. Then you'll be able to know for sure if they machine some of the pulley away. If they do, and you install a pulley with an incorrect offset, you may have belt breakage/premature wear.

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    Click here to enlarge Originally Posted by BlownE92M3 Click here to enlarge
    I thought they didn't/couldn't custom tune????
    They certainly do. Sal has tweaked my file testing on the street and at the Dyno (Mac Autosport in Parker). He will need you to log some data parameters but you will be in great hands.

    Afterall, they do have their own blower kit and have proven their tuning abilities on many other S/C kits - including ESS's own kits.

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    Click here to enlarge Originally Posted by BlownE92M3 Click here to enlarge
    I thought they didn't/couldn't custom tune????
    they certainly CAN.

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    Click here to enlarge Originally Posted by THATDONFC Click here to enlarge
    Are you sure ESS does not machine away some of the pulley? You should put the pulleys side by side, on a flat surface, with the face of the pulley that rests on the blower shaft down. Then you'll be able to know for sure if they machine some of the pulley away. If they do, and you install a pulley with an incorrect offset, you may have belt breakage/premature wear.

    I was told mine was the only one that was machined down. either way, he could always just PM the other ESS guys, they seem to have toolboxes full of different pullies for different events.. ask me how i know Click here to enlarge

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    3 out of 3 members liked this post. Yes Reputation No
    Click here to enlarge Originally Posted by BlownE92M3 Click here to enlarge
    I recently opted for the ESS 625 kit. Originally Andrew (owner of AR Design/Alpha Motorsports here in Colorado) and myself were going to swap pulleys and re-tune the car to make up for the harsh elevation hit in power. We are running into an issue here though with the pulley/tune situation. We spoke with ESS and they are not willing to give any info on pulleys or offer a different tune to compensate for an aftermarket pulley/elevation. We ordered a vortech pulley, but noticed ESS machines a damn offset into the 625 pulley supplied. So my questions are:

    1. For those who swap pulleys, how do you go about doing so since ESS machines an offset into their pulleys in the kits?

    2. My car made 526hp SAE (mid 400's uncorrected i think) so what would be a "SAFE" number to shoot for up here in Colorado? I figure if I can get her to an actual 500-520 UNCORRECTED (which would show 600+ corrected up here) would be nice up here in this horridly thin Colorado air.

    3. TUNING..... My biggest issue. Are there any vendors that offer custom tunes for these cars, or any stand alone routes (EMS/Motec/ProEFI) that are available to us? Is it possible to switch over to E85? If so, what fuel components need to be upgraded?

    Sorry if these are noob questions. My previous cars/bikes were not locked down like this damn M3 is, and tuning is such a freaking issue with this car. Thanks
    Click here to enlarge Originally Posted by flipm3 Click here to enlarge
    Not trying to open up any cans of worms, but have you considered contacting @evolve since they have custom tuned a few BMWs in CO. One of them being an E46 M3 with a ESS VT2-500 owned by @normcaldwell .
    Click here to enlarge Originally Posted by MisterEm Click here to enlarge
    They certainly do. Sal has tweaked my file testing on the street and at the Dyno (Mac Autosport in Parker). He will need you to log some data parameters but you will be in great hands.

    Afterall, they do have their own blower kit and have proven their tuning abilities on many other S/C kits - including ESS's own kits.

    Denver altitude centrifugal forced induction owner checking in with my nickel . . . .


    For both of my ESS Vortech based kits ('03 330xi, '06 M3) I went down two pulley sizes. Purchased the pulleys direct from Vortech, and took them to BimmerHaus. The guys at BimmerHaus had the pulley stems machined down to match the length needed for the ESS kit fitment. In both cases, I went from an ESS-delivered pulley size of 3.33" to 3.125" (two sizes down). About a 5mm difference in diameter. Both kits were advertised as a 7 p.s.i. kit. To get 7 p.s.i., I had to go down the two pulley sizes. At this altitude, these kits are not worth having unless you can run an airflow similar to the sea-level flow for which the kits are developed and advertised.

    In both cases, I know I am still not exceeding the maximum impeller speed advised by Vortech. For example, the V-3 Si has a max impeller speed of 52,000 rpm. On my '06 M3, at 8,000 rpm (redline for my setup) the impeller speed is just under 49,000 rpm; a good 3k rpm below max. Dropping 5mm in s/c pulley size at this altitude goes quite a ways towards having the kit perform more like it would at sea level. Nothing fully compensates for the high density altitude factor, but it sure helps.

    In both cases, with the smaller pulley, I ran the same ESS software (for 91 octane fuel) that came with the kit. No AFR issues, or any other issues. I have a thread in the S54 section showing comparative dyno runs with the ESS delivered software and Evolve calibration file. I've stayed with the Sal's tune because I like it better for all aspects of driveability and power.

    By the way, if you go with a smaller s/c pulley or Evolve calibration (I would not do one or the other, I'd do both) and the ESS boys find out, they will no longer warranty their hardware and will no longer 'support' you with their software. Their hardware is pretty good, so I don't need a warranty on that anymore. Their software is not as good as Evolve's, so I don't need that anymore either.

    I have 16,000 miles on the kit, went with the smaller pulley from the start. About 13,000 of those miles are with the Evolve tune. I'm very pleased with how the car drives. Uncorrected rwhp is, of course, still well less than SAE, but at least the SAE results are more in line with the kit's advertised numbers. (Actually, it's higher, but the SS V1 stepped headers/HJS catted section 1 has a lot to do with that; plus the Evolve calibration).

    I hear you on the overall tuning situation. The good news is that we at least now have some excellent tuners for the S54, S62, S65, engines, and the tuning can be done remotely and updated within a couple of minutes during dyno sessions.

    I'd be happy to meet or at least further discuss via PM, post, etc. Let me know if you have any questions.


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    Click here to enlarge Originally Posted by normcaldwell Click here to enlarge
    In both cases, with the smaller pulley, I ran the same ESS software (for 91 octane fuel) that came with the kit. No AFR issues, or any other issues. I have a thread in the S54 section showing comparative dyno runs with the ESS delivered software and Evolve calibration file. I've stayed with the Sal's tune because I like it better for all aspects of driveability and power.

    By the way, if you go with a smaller s/c pulley or Evolve calibration (I would not do one or the other, I'd do both) and the ESS boys find out, they will no longer warranty their hardware and will no longer 'support' you with their software. Their hardware is pretty good, so I don't need a warranty on that anymore. Their software is not as good as Evolve's, so I don't need that anymore either.
    quoted for TRUTH!

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    1 out of 1 members liked this post. Yes Reputation No
    Well $#@!, looks like im bringing the pulley w/ different offset to a machine shop and hitting up evolve very soon for a new tune!
    -08 E92 Brushed Steel DCT 613hp-
    -ESS/AR 700 - KW V3's - AR Design - Volk TE37 - Vorsteiner - Challenge-
    -2012 Brushed Red Aluminum GTR-
    - Jacks 3.8 w/ Jacks heads - Jacks Drag 800 w/ billet gears - AAM GT-900R - Swift - ADV.1 - Ecutek via Visconti -
    - 1060hp 852tq 32psi - 9.34 @150mph 7688ft DA - 185.5mph 1/2 mile 9240ft DA -
    http://www.jackstransmissions.com/
    http://store.vtune.us/
    http://www.revvolution.com/

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