03-23-2010, 10:34 AM #1
'99 M Coupe Turbo: Top Mount PT6262
I know I know, it's not an S54, but I have so many things to post that are pre-S54 that you guys just have to deal haha!
Sick build from a guy on Supra Forums...
...well, it may not be epic by Supra standards, but it is by BMW standards. as the title suggests, my brother Brian has been performing surgery on his 1999 Z3 M Coupe for the past month or so with the help of our good friend and fabricator Shawn of Fifteen52 (1552v2.com). i originally wanted to start this thread back when Brian first started the project, but i just didn't have the time until now. at this point, the build part of the project is essentially done and is just awaiting a tune. however i will do my best to "cut and paste" the pictures and updates from another forum so that you can all see any and all previous progress and ask questions. i'm sure some of you are members on one or more of the boards we posted a build thread on (such as bimmerforums.com), and may already be familiar with this particular build. nevertheless, i thought this would be a good place to post it as well, since we're all boost junkies here too. currently i don't believe either Brian or Shawn are members here, but i will get them to create accounts so they can converse and field questions as well. by the way, this isn't an engine build, just a turbo build, and so this is being done on a stock S52B32 block and head. so without further ado, on to the build...
- Precision PT6262, Billet Wheel, 4” Inlet, 3” V-band exhaust, .81 a/r
- Tubular Top Mount Manifold
- Tial 44 Wastegate
- Aluminum Intake manifold w/ front mounted throttle body (Supra style)
- MLS .140 head spacer
- ARP head studs
- Precision 750hp FMIC
- 3” Intercooler plumbing
- Tial 50mm BOV
- 3” SS Turboback Exhaust
- Mocal Oil Cooler with Ireland Engineering Filter cap
- Dehrale Power Steering Cooler
- AEM Truboost EBC
- AEM Uego Wideband
- AEM water/meth
- MaximumPSI Fuel Rail with 6an feed and return
- Aeromotive FPR
- Aeromotive 6an inline filter
custom tune by Nick G. (for those unfamiliar with Nick, he is THE man to go to for your BMW turbo build tuning needs...he is revered as a god in the BMW world)
power goal: 500whp on 93 octane, 600+whp on 100 octane & meth
rough turbo placement (notice the sheet metal that was hammered to make the exhaust side of the turbo fit):
03-23-2010, 10:39 AM #2
03-23-2010, 10:43 AM #3
03-23-2010, 10:47 AM #4
space is a HUGE constraint on this project...so much in fact that you'll note later in the thread (when i get to those pictures) that the manifold cannot be installed or removed without taking off the head (i.e. the head must be removed, then the manifold bolted to the head, and then reinstalled on the block as one piece). people on other forums have also asked what we're doing about a charge pipe or intake filter...well, the answer is quite simply "nothing"...just a screen is going to cover the turbo inlet b/c there is no room between the turbo and the back of the front right headlight for a filter or velocity stack (horn).
people often don't realize that, even if the motors are identical, the spaces and clearances under the hood of an e36 M3 and a Z3 M Coupe are VERY different. so naturally we've gotten quite a few responses on some of the BMW forums telling us that there are easier ways to do this or that simply b/c they've done it on their M3s...but the truth is many of them don't know their folly b/c they've never actually tried the same thing on an M Coupe.
also, another giveaway is the mainfold design - if we weren't so tight for space on the exhaust side, the manifold would look and flow better than it probably does. but no worries - it will flow more than enough to easily reach the power goal, and then some.
forgot to post pics of the intake manifold as it came together...here ya go:
03-23-2010, 10:50 AM #5
exhaust manifold completely tacked and ready for welding ...by the way, one of the most amazing things about this build is the fact that, while Shawn has been working on cars for quite some time now, this project is the first in which he handled all of the fabrication himself...he basically taught himself to TIG weld on this project, and you'd never know he's that new to welding judging by the welds you'll see shortly:
03-23-2010, 10:55 AM #6
03-23-2010, 10:59 AM #7
03-23-2010, 11:06 AM #8
03-23-2010, 11:13 AM #9
Some more progress
Fuel basket with Walbro 255lph hi pressure Intank pump, 6an feed from pump to rail
Oil pan tapped for oil return
Final fuel lines complete, added FP gauge inline
Some more progress on the little stuff!
Coilpack harness rewired to exit at the rear of the loom
02 sensors (wideband for tuning, and wideband for in car display
Split the uprights
Oil cooler found its new home
3" charge pipe fits!! Hydraulic timing chain tensioner clears my collector perfectly!
Intake manifold modification to better fit the car and placement of the throttle body now that the rest of the pieces are in place
03-23-2010, 11:20 AM #10
03-23-2010, 11:27 AM #11
New throttle cable just arrived. Had to make a new bracket to hold the TB side cable end. The factory bracket didn't allow for the correct clearance or allow any adjustment to get the play out of the cable. So here you go, now we can
Picked up the fittings and line for the oil cooler today and got started on that this evening
We oddly enough picked an oil cooler which uses inverted flare fittings. To get them to the standard blue/red fitting had to cut the fitting supplied with the cooler and weld on AN standard flare fittings
After their surgery
Well guys we are almost there! Waiting on a few last pieces to finish up the fab work, AEM water/meth and HKS muffler so I can finish up the exhaust. Other than those two things engine wise we are set to go! Wideband and EBC still need to be installed and wired. By that time we should have our base tune from Nick G and be ready to head to the east coast for Nick to custom tune the car in person on the dyno.
I want to thank everyone that has been following the build. I appreciate everyones comments and input along the way! My fab guy ( Shawn @ www.1552v2.com)started this project 100% new to fabrication work of this sort and having never touched a TIG before, it was surely a learning experience for him! Thanks again for the support throughout and we should soon have the dyno #'s and videos we have all been waiting for!
So, who's ready?
03-23-2010, 11:30 AM #12
03-23-2010, 11:33 AM #13
03-23-2010, 11:35 AM #14
03-23-2010, 11:36 AM #15
03-23-2010, 11:40 AM #16
ok, here are Brian's and my (Supra) dyno results, back to back:
i thought some of you might find this information useful in trying to reconcile HP/TQ output with our brief race results posted earlier in the thread
...a few things to keep in mind. first of all, i was running 100 octane and 18psi on the dyno, unlike the 16psi and 93 octane i ran during our race. i'm sure on 16psi and pump i'm making a bit less power. likewise, if my boost controller were holding 19-20psi like its suposed to, i would have dyno'd higher.
...on to Brian's car - he was running 12-13psi and 93 octane both when we raced and on the dyno. after the custom tune happens in a few weeks, we're expecting closer to 20psi. in addition, the current (interim) tune is causing him to run pig rich, so there is a significant amount of power to be had simply by appropriately leaning out the tune. so between that and the added boost, i suspect at least 550whp on pump and 600+whp on race gas easily.
03-23-2010, 11:41 AM #17
03-23-2010, 11:46 AM #18
well it didn't literally "pop" b/c the gaskets are fine and absolutely no fluids spilled. that being said, what i gathered from a brief conversation with my brother is that a valve gave way, fell into the firing chamber, got kicked back up into the head by the piston as it was moving back to TDC, and did some damage to the rest of the valve train. after showing the valve to an experienced auto machinist, they found marks on the valve stem characteristic of using nitrous (which my brother used in his previous setup before getting boosted). so we believe that the change in heat cycling due to going from a nitrous setup to a boosted setup weakened the valve stem and caused it to fail - hence the reason it fell into the firing chamber. once i get more details i'll know if this is an accurate description of what happened or not.
ok ,well i guess it all got documented over at bimmerforums.com...looks like i missed alot while i was away for the weekend. it turns out i was wrong - there is quite a bit of damage to the block as well as the head. as i said above though, they're going to source an M50 or an M52 as opposed to cleaning up the S52 block. i will update this thread with pictures of the damage as soon as bimmerforums is no longer down for maintenance...
The plug, remaining piece of valve, and some valve seat shrapnel that made its way from the head into the intake manifold.
03-23-2010, 11:49 AM #19
Well Brian's turbo M Coupe is up and running again...he's back, this time with an M52 on stock bottom end (for now) with new rings, bearings, and main studs. The head has re-lapped valves, S52 cams, cam trays, and valve springs, as well as new valve seals and retainers. Head gasket is a .140" mls for 9:1 CR. Everything else is the same setup from the S52. Basically it's a fresh motor, and bc we replaced many oem parts, it runs smooth as silk. Started up first time no hesitation on same base tune as before. Clutch is shot, so Brian will need to find a solution soon b/c it'll be on Nick G's dyno in about 3 weeks.
some of you may also be wondering why the Work Meisters are on Shawn's Roadster instead of Brian's Coupe. well Shawn got tired of the OEM wheels in no timer whatsoever (what else is new), and since Brian's car was out of commission for such a long time, he let Shawn borrow the Meisters. well now Brian wants some CCW Classics with gold centers, though he isn't in the market for them yet. so i don't know whether he'll take back the Meisters until he can afford the CCW's, or if he'll just let Shawn keep them while he rolls on Shawn's OEM wheels.
03-23-2010, 01:26 PM #20
dude sick build thread, i have a friend who loves the shoe! (e46 m coupe). he'll die when he sees whats under the hood lol. i also am admiring the craftsmanship, nice work!
2007 335i Coupe
Mods: Check the Garage
03-23-2010, 02:02 PM #21
Yeah when I first saw this car on Supra Forums, I was very excited to see someone taking on a unique project that would result in a brutal street machine.
My dad actually has an '01 Z3 Coupe 3.0i with the M54 - stock forged crank and connecting rods. I've been trying for several years now to get him to boost it.
03-23-2010, 06:06 PM #22
03-23-2010, 06:55 PM #23Member
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Absolutely sick car, my favorite all-time m-coupe, but I think it is no more. If I am thinking of the right car, it was unfortunately totaled a few weeks back. After looking at the accident pictures it was unreal that the passenger lived.
03-23-2010, 08:50 PM #24
03-24-2010, 07:25 AM #25