The it was supposed to be just an oil pan gasket project

[Sockethead]

So what was supposed to be just an oil pan gasket snowballed into a 3 week "while I'm in there" project.

http://uploads.tapatalk-cdn.com/20160711/5c6b718f12957e9b48a62f42befdac03.jpg

We want to keep this car for a really long time so I thought it would be a good idea to address a few weak points on the car.
The oil pan removal was pretty strait forward: move a bunch of stuff out of the way do the oil pan can be removed.
I got an engine support bar from Harbor Freight for around $60 after using a 25% coupon.

http://uploads.tapatalk-cdn.com/20160711/e7fc426380cdb38562f5118ff27d93ed.jpg

It worked really well and a good solid unit.

Partial pile of parts to go in

http://uploads.tapatalk-cdn.com/20160711/c3ec235247b92d3d52b526ee9cf5ead8.jpg

Parts removal pile is growing

http://uploads.tapatalk-cdn.com/20160711/3397ff14e6233650c1865bf3b0a0de9f.jpg

Dropped the crossmember onto a floor jack and unbolted the the steering rack. It was much easier this way. I supported the rack with some bungies. I didn't remove the steering column joints ( thanks for the tip Vas)

http://uploads.tapatalk-cdn.com/20160711/dec19aebf684ab5f9ece387d62af0e5a.jpg

I completely removed the crossmember with the lower control arms still attached.

http://uploads.tapatalk-cdn.com/20160711/17e4e8b27f2c6aa72da206020b713d83.jpg

I was amazed that after 141k hard miles, my lower control arms were in almost perfect shape with no real play in any of the joints. I probably could of gotten another 40k out of them but they're getting replaced because... While I'm in there...
Also, my motor mounts were in perfect shape. I was really surprised by this. I thought for sure after all the milage, hard driving, track day and drag strip runs that they'd be shot. They're getting replaced too.

oil pump removed:

http://uploads.tapatalk-cdn.com/20160711/ee4a950e630f45862205709e96034ee2.jpg

I replaced the oil pump with a rebuilt Achilles Motorsports pump. This pump a new shaft & sprocket that is keyed differently. It also uses a bolt instead of a nut and is driller for safety wire.


I thought I had some pics of the new pump installed but I don't

This is the famous oil pump nut. Mine wasn't loose at all and took a normal amount of effort to remove.

http://uploads.tapatalk-cdn.com/20160711/f9acec32660ab08a98cebfe0aad31e49.jpg

This shaft sometimes shears off too.

http://uploads.tapatalk-cdn.com/20160711/75531cbcb1dc2c6ff16ed0d9e0f0c113.jpg

You can see the original oil pump and sprocket hanging down in this pic. Replacement is just like replacing any other part. You just need to prime the pump with oil before installing it.

http://uploads.tapatalk-cdn.com/20160711/444e231f1edcd9fa200db7ad89d806b6.jpg

As long as the oil pan was out, I decided to install a baffle.
Here's the original baffle

http://uploads.tapatalk-cdn.com/20160711/488be422cac10c98aafc2da39df9f185.jpg

I drilled out the rivets and pryed it off.

Test fitting the VAC baffle

http://uploads.tapatalk-cdn.com/20160711/0281125314718fb860562580a7707509.jpg

I had a few issues getting it to fit properly but when I sent it to the machine shop for hot tank and welding, it fit perfectly. I have no idea what I was doing wrong

http://uploads.tapatalk-cdn.com/20160711/7bd0f19a63af48c607d48a4703d8511b.jpg

http://uploads.tapatalk-cdn.com/20160711/b691aef78069bc6fa63700e311f31ff6.jpg

Reinstallation of the oil pan was uneventful. There were two bolts/holes that I had to retap. I used a BMW gasket and used standard Silicone goo to seal up the seams in the front and back where the timing chain cover joins the block. I forget what the seam is in the back.

More to come...

[Vas]

Nice job man :) Glad to hear you got it done in your garage

[BMWCurves]

Damn, that's a lot of great stuff! Sounds like the car will last you a long time.

[Sockethead]

Nice job man :) Glad to hear you got it done in your garage

Yea it was pretty rough laying on the garage floor in 100 degree heat. I needed to get it buttoned up before San got here to swap exhausts so there were several 2 am nights. At least it was a bit cooler then. It was tough working round the twins schedule. I usually didn't get started until after 9 at night

[WOLFN8TR]

Most Excellent work!! I hear ya on the 100 degree garage heat. I spent the weekend out in the garage working on my car. The heat really wears you down after awhile. [emoji45]

[Vas]

Yea it was pretty rough laying on the garage floor in 100 degree heat. I needed to get it buttoned up before San got here to swap exhausts so there were several 2 am nights. At least it was a bit cooler then. It was tough working round the twins schedule. I usually didn't get started until after 9 at night

Sounds just as bad as me doing it outside on black asphalt lol.

No leaks to report?

[Sockethead]

Most Excellent work!! I hear ya on the 100 degree garage heat. I spent the weekend out in the garage working on my car. The heat really wears you down after awhile. [emoji45]
It sure does. I just took my time and a couple of fans going. That alone made a big difference. It was hard keeping the sweat from dripping on everything. I was pretty much soaking wet

[Sockethead]

Sounds just as bad as me doing it outside on black asphalt lol.

No leaks to report?

Black asphalt is much worse! At least my garage floor is perfectly smooth, cool concrete.

No leaks! I was pretty paranoid about that; thinking about the nightmare of taking everything apart again...

[Johnmadd]

Nice work Rob. So when does fi come into play?

[Sockethead]

Nice work Rob. So when does fi come into play?

IDK. I really wanted to use the Technique Tuning Turbo but Nick G has lost interest in the e46. There isn't anyone else doing a turbo kit and I don't have the time or resources to build one from scratch (which is what Kristen wants me to do). The ESS TS2 is out of production for the time being.
Those two kits, in my opinion, are the only two kits out there that are worth the price so FI is pretty much on hold for the time being.

[Sockethead]

Crossmember:

I always wanted to do the TMS front subframe reinforcement kit but who want to pull the crossmember without a good reason?
In hindsight, the reinforcement is probably unnecessary since I'm still using rubber motor mounts but for $40, what the hell...

This is the area that gets reinforced

http://uploads.tapatalk-cdn.com/20160711/15e30d5d33a85d5382a74daef660ba0e.jpg

I had the motor mount ears media blasted for a clean welding surface

http://uploads.tapatalk-cdn.com/20160711/f45c2c4ca0bb81404b1d6b0f32b2d67f.jpg

Then I welded in the reinforcement backing plate. This strengthens the actual mounting surface by doubling its thickness.

http://uploads.tapatalk-cdn.com/20160711/5ec6f5962eb1386b124a84c4078ca29b.jpg

Next I welded in the additional ear support. The strengthens the whole ear and keeps it from twisting.

http://uploads.tapatalk-cdn.com/20160711/f42f5e9e4f7764146f22d010d383b336.jpg

I was really disappointed with the quality of my welds but I was working with an under rated AC line and a constantly tripping breaker in the rental house. It made it impossible to get a good consistent bead. Oh well, it is what it is it still got pretty good penetration so it was off to the powder coater.

The finished product looks great!

http://uploads.tapatalk-cdn.com/20160711/0839c7e150a73898b65c05c9d751c0b4.jpg

Even the welds look better

http://uploads.tapatalk-cdn.com/20160711/782a5d8a936ca4de9f41d2896d5857f5.jpg

One reason I went with powder coating is that my crossmember was starting to rust and pit pretty bad around the edges. The only way to remove that is media blast and as long as it there, might as well get it powder coated. It was only $75 for media blast and powder coat.

I got new Lemforder control arms and bushings from FCP. I had a can of clear wheel coating so I decided what the hell and spayed the control arms.

http://uploads.tapatalk-cdn.com/20160711/8af7cea837b189e5f341ae30dd0bc65d.jpg

My old ones looked so nasty, maybe this will keep them nice for a while.

With the crossmember done it's time to move on to the headers....

[squashman702]

Just did the AKG plates on my M3- ended up using my sand blaster to clean it up too. What are you using for a welder?

http://i243.photobucket.com/albums/ff295/squashman702/20160707_181137_zpsrjiswcks.jpg (http://s243.photobucket.com/user/squashman702/media/20160707_181137_zpsrjiswcks.jpg.html)
http://i243.photobucket.com/albums/ff295/squashman702/20160709_123724_zpsp6wdumlw.jpg (http://s243.photobucket.com/user/squashman702/media/20160709_123724_zpsp6wdumlw.jpg.html)
http://i243.photobucket.com/albums/ff295/squashman702/20160709_125533_zpshzcqe7qx.jpg (http://s243.photobucket.com/user/squashman702/media/20160709_125533_zpshzcqe7qx.jpg.html)

[Sockethead]

I have an ESAB Miggy 125 from the 80's. I had to modify it with a Euro adapter to accept a Nu-Tec Binzel style gun as ESAB stopped supplying parts for these long ago. I was running .023 because at one time, I was doing a lot of body work. The new torch came with .030 tips so I'm using that now. I use a 50/50 argon C02 mix. It's been a damn good machine over the years with a decent duty cycle.
It usually runs good on a 15 amp circuit. I don't know what happened this time but it's a rental house so I can't mess with the wiring

[squashman702]

Gotcha. I have a Miller 211 and am running .030" wire.

[Vas]

Man wish I knew how to weld.

[Sockethead]

MiG welding is pretty easy.... almost like using a glue gun. if you're interested, Miller makes a unit that's set and forget for most metals. There are a ton of instructional videos on YouTube.....

[squashman702]

MiG welding is pretty easy.... almost like using a glue gun. if you're interested, Miller makes a unit that's set and forget for most metals. There are a ton of instructional videos on YouTube.....

Agreed. I'd argue that MIG is the most useful for automotive applications, due to the fact that it's probably easiest to weld out of position. I've done some stick, which I enjoy, and a little bit of TIG of mild steel.

[Sockethead]

I learned on stick back in the late seventies. I also learned that stick welding is very unforgiving. I haven't tried TiG. I like to learn though...

[san]

I had to do a lot of arc welding for the dune buggy I built back when I was in undergrad, learnt the hard to have proper eye protection...


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[Sockethead]

I had to do a lot of arc welding for the dune buggy I built back when I was in undergrad, learnt the hard to have proper eye protection...


I was working in a truck shop and this old guy came in to do some cutting and welding. He was using the cutting torch without any goggles. When I asked him about it, he said he never used them. That night he gave me a ride home.... I thought I was going to die.... Every time car came from the other direction, it blinded him and would run off the road. It wasn't much better when there weren't any cars. That night I made a mental note to never, ever do any cutting or welding without proper eye protection...

[Sockethead]

I got a pair of bimmerbrakes gen 3 headers from euro parts online. When they arrived, they had a euro parts online logo plate welded on them which made me very skeptical that they were bimmerbrakes headers but after reading some threads on E46f I figured out that apparently, the guy that owned bimmerbrakes now owns or works for euro parts online and the headers look the same as every pic I could find so, off to the installation. The old manifolds came off pretty easy. I had already replaced the bolts at the exhaust system joint when I got my Corsa so they were easy as were the pre cat 02 sensors. I left the post cat sensors on and disconnected the wires at the top of the motor.
As everyone said would happen, all the studs came out with the nuts but NBD I already bought new ones. Once they were out, I removed the post cat sensors which came out surprisingly easy considering the mileage on the car. No penetrating oil or heat needed.

Without the motor mount, crossmember and oil pan in the way, the there is a lot of room to work

http://uploads.tapatalk-cdn.com/20160712/586d3bc14dd96c2cef7d04068a7cf7d9.jpg

View from the top without the SAP in the way

http://uploads.tapatalk-cdn.com/20160712/176cfb9e3c63682fc03c7e7e8b189327.jpg

Installing the headers was the most tedious frustrating thing I've done on the car. It surpasses the M3 mirror retrofit by a lot.
There are few bolts that are nearly impossible to get to due to the routing of the tubes. I spent several hours and flipped out twice before I got them torqued to spec. Some say they are easier with the heat shields removed from gaskets but I wanted to keep the shields since the valve cover is plastic. Plus I think it be only marginally easier.
I eliminated the post cat sensors and plugged the bungs.

View from the bottom... It sure is pretty

http://uploads.tapatalk-cdn.com/20160712/1e45784729220234af5141e57fcc2993.jpg

The 02 sensors are a tight fit in this space there is plenty of wire to reach down here

http://uploads.tapatalk-cdn.com/20160712/955a3f809d25eab718736916e5c85576.jpg

View from the top. I eliminated the SAP all together since it's not needed

http://uploads.tapatalk-cdn.com/20160713/270f132f3d6e0fd626bf11e5cfa0f890.jpg

I ordered a block off plate from the dealer to block off the hole for the SAP valve

http://uploads.tapatalk-cdn.com/20160713/10fb2298dc7709b67981c5331d9862af.jpg

Crossmember and new LCA ready to go in. I wish they would stay this clean ....

http://uploads.tapatalk-cdn.com/20160713/382517839bfe780d7e2b681840cdde57.jpg

I didn't hookup the exhaust right away because San was coming down to swap his ZHP exhaust for my Corsa. In hindsight, I wish I had just to see how loud it would be. The ZHP exhaust isn't really that much louder with the headers just some rasp
Anyone looking to install headers but worried about the noise, I can say that isn't an issue at all with the stock ZHP exhaust. It may be a bit too quiet for me

https://vimeo.com/174438281

https://vimeo.com/174438308


Kristen said she was giving about 1/2 to 3/4 throttle in the drive by

How do I like the headers? The car seems to pull better throughout the whole RPM range. It definitely doesn't feel as anemic as it did with the stock manifolds. I like the sound of the exhaust too although it could be a touch louder. It's pretty raspy... Rasp seems to be something people either love or hate... I like it.

As for real numbers, I found a place in North Charleston that has a dyno. I have an appointment on Saturday. I'm hoping for something at least over 200 hp. My last dyno run a few years ago was a disappointing 191 hp and that was with the dinan CAI, throttle body and stage 3 tune.

[Hornung418]

Excellent work! I'm glad your headers were machined properly...as you may remember, mine needed a donut spacer to connect the stock exhaust with the header flange. Do you have a link to the replacement oil pump gear?

[Sockethead]

here you go... looks like the price went up a bit since I purchased mine
http://www.achillesmotorsports.com/Achilles-Upgraded-Oil-Pump-BMW-E46-Z3-Z4-M54-M52TU-p/11-am-uopr-m54.htm

[Hornung418]

here you go... looks like the price went up a bit since I purchased mine
http://www.achillesmotorsports.com/Achilles-Upgraded-Oil-Pump-BMW-E46-Z3-Z4-M54-M52TU-p/11-am-uopr-m54.htm
Nice! That looks like a very solid solution. The only other one I've seen that combats this issue is the one on Bimmerworlds website. It was originally designed by an enthusiast.

Sent from my Nexus 6P using Tapatalk

[Sockethead]

I thought about that one but decided it was a little overkill. VAC motorsports has a shaft and sprocket but I've read of several failures with that.

[slater]

great work, rob! :cheers

i recently inspected my front lower control arms and found the same thing - no play whatsoever, and i'm at around 145K miles.

[Sockethead]

Thanks Peter!
Yea, I've found that a lot of the rubber bits I've swapped were still in excellent shape: Motor mounts, lower control arms, RTAB... I examined the rubber bit in the steering column while I had a good view of it and it's still in perfect shape... The only ones that have failed are the LCAB, RMS and the rear diff bushing

[squashman702]

How did the car do on the dyno?

[Sockethead]

Pretty crappy. It was in the 90's and in the middle of a thunderstorm by the time I got it on the dyno. I'll post after I get the SAE corrected graph so I can properly compare it to my last run a couple of years ago...

[Sockethead]

I've had some more seat time since I put the headers on and removed the Sprint Booster. The headers made a significant improvement. The car makes more torque throughout the whole RPM range and it's more responsive... It's almost like the Sprint Booster is still in there. I'm impressed! I loved the Sprint Booster but the car doesn't need it anymore...

[rkneeshaw]

Glad you got a before dyno, that will be real handy once you install the TS2 kit.

I'd strongly recommed you pick up a copy of Renovelo's bytelogger. I'd love to see a datalog on your car before and after the TS2 install too. And, its very useful for making sure the tune from ESS is all on par. I've got a transfer function that converts your pre-cat O2 voltages to an AFR reading, so you'll know if you're running good or not before and after.

I bet your dinan TB might demand a few tweaks possibly?

Are you running without any tune at all now? You must be getting the SES light for the SAP and headers.

Don't forget to tell the ESS guys to turn off the SAP too, they can do that now ;)

[Sockethead]

I don't want to beat a dead horse but I still can't get over how well the car runs with the headers. This is the way the car should of come from the factory.
Anybody on the fence about doing headers, it's totally worth it.

[slater]

I don't want to beat a dead horse but I still can't get over how well the car runs with the headers. This is the way the car should of come from the factory.
Anybody on the fence about doing headers, it's totally worth it.

rob, you're not helping me here... i've got a set sitting on the parts car!! :)

as ryan mentioned above - how are you handling the CEL from O2 sensor and SAP delete? curious... ;)

[san]

rob, you're not helping me here... i've got a set sitting on the parts car!! :)

as ryan mentioned above - how are you handling the CEL from O2 sensor and SAP delete? curious... ;)

He had terraphantm code it out for him when he got the m3 cluster


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[slater]

He had terraphantm code it out for him when he got the m3 cluster


Sent from my iPhone using Tapatalk

aha! smart thinking. :)

[johnrando]

Nice!

Sent from my SM-G935V using Tapatalk

[Vas]

Rob, How much were the headers if you dont mind me asking?

[Sockethead]

I got them here: http://www.europartsonline.com/bimmerbrakes-gen3-m54b25-m54b30-performance-headers/

[Vas]

I got them here: http://www.europartsonline.com/bimmerbrakes-gen3-m54b25-m54b30-performance-headers/
Thanks.

[BMWCurves]

That's not a bad price. Did you go catless?

[Sockethead]

Yes catless with the stock ZHP exhaust. There are some sound clips earlier in the thread if you want to check out how it sounds...

[Sockethead]

Just when I thought I was wrapping up this project, a few more things came up. The drivers windows regulator is starting to pop, the drivers side c pillar fabric is flapping in the breeze and we got pulled over by the cops for the license plates lights out. In addition, while I had the pan off looking around, I noticed that the high pressure hose for the power steering is starting to weep. I just replaced the windshield cowl because it was starting to crack... The car is starting to show it's age....got the window regulator on order... I guess I'll try gluing the fabric back on and hopefully the license plate/trunk assy. won't fall apart when I replace the bulbs

[Johnmadd]

Yeah, my b pillars are shot and I desperately need a paint correction session. I also need new diff bushings. How many miles on yours, I'm about to crack 183,000.

[Sockethead]

I think I'm at 142k now... yea, I forgot about the paint correction.... black cars....

[Johnmadd]

Last black car I will ever own, unless a crazy deal comes along or I win the lottery.

BP said he pulled all the pillar fabric and nobody even noticed at the reunion, I didn't. I'm thinking of doing the same. Maybe they could be smoothed down and platidiped to match the plastic center console, I'm desperately trying to figure out some sort of solution that no one has thought of and posted about it.

[Vas]

I pulled the fabric off on the wife's zhp on the b and c pillars.

It's fine for the time being but it's still not the same material under as the top that peels. My ocd won't let me leave them.

The rear are not too crazy to replace but the b pillars are expensive.

As far black, it's a hate it and love it relationship.

[johnrando]

Needless to say, but love black on the right car.

Sent from my SM-G935V using Tapatalk

[Sockethead]

I love my black car... so damn sexy but a bitch at the same time

[ELCID86]

Pull the c pillar fabric and see if you even notice for a few weeks.


---
"ZHP is a garbage option anyway- just some cosmetic upgrades with a different cam and diff to claw back some of the performance lost fitting those hideous and heavy wheels. Any 330 with a 3.46 diff will smoke a ZHP every time. The whole Mafia thing reeks of childish behavior." - anonymous

[fredo]

Here are some pics of pillars with no fabric. Granted, pics are under the sun. Inside the car won't be as visible.

http://www.zhpmafia.com/forums/showthread.php?17178-Fabric-removal-on-A-amp-C-pillars

I had an idea. Some people paint the rear deck. What about painting the pillars without fabric ? :dunno

[Sockethead]

what about gluing them back on with some 3M spray adhesive? Does the adhesive bleed through the fabric?

[Vas]

Fabric is really thin and doesn't stretch well

[Sockethead]

I've been putting off posting my latest dyno run because it was so awful. But I guess I'll post now.
The atmospheric conditions were about as bad as it gets: in the 90s, high humidity and we were in the middle of a thunderstorm during the run. To top it all off, I don't remember turning off the air conditioning. It was a total fail.

The first graph was from a few years ago in perfect weather conditions: in the 70s, low humidity, high pressure weather system in place.

http://uploads.tapatalk-cdn.com/20160802/0e4d181cffc71e44668d4bbbd7cf31fa.jpg

I expected to a least get over 200hp out of the car but didn't quite get there
I did notice that torque is up throughout the whole graph and this is very noticeable from the driver's seat. I really like the way the car performs everywhere in the RPM range. I bet these numbers would be higher in ideal weather conditions.

[san]

So you are pretty much in the same ball park as before in terms of peak power, but peak torque went up in much worse ambient conditions... 200hp should be achievable I guess...


Sent from my iPhone using Tapatalk

[Sockethead]

Yea torque is up significantly while HP barely did anything. I can definitely feel the torque every where and that's the more important number

[rkneeshaw]

Got any new pics of your engine bay? :devilish

[Sockethead]

Lol, no, not yet. It's hard to find the time to work on it

[rkneeshaw]

k, I was just wonderin'... :)

[Sockethead]

Discovered the bearing the the tensioner pulley is shot. I thought I just replaced that a year or two ago. I'll have check my receipts and see if I can get a free one from the dealer

https://vimeo.com/178803001

[Vas]

Good catch

[Sockethead]

I never would of noticed it if the trouble light wasn't laying on the floor shining up at it. I had the splash pan off at the time. Sucks because I literally just replaced the tensioner...

[ELCID86]

Glad you spotted it. Replaced yet?

[Sockethead]

no... I gotta get Kristen to pick it up for me. The parts dept. at her dealership really sucks . They never have anything in stock and it takes a couple of days to get it... still a few dollars cheaper than online... for OEM anyway.

[Sockethead]

I been pretty busy lately with family visiting, kids, new job, building a house, etc. I haven't had time to update here.
I think this is the pic Ryan was looking for a couple of weeks ago

http://uploads.tapatalk-cdn.com/20160826/a595a91f9957fceefbac0b0a134c2e16.jpg

[Vas]

No way

[Karl Lazlo]

What is that thing hanging off your intake? That doesn't look right.

[Johnmadd]

I been pretty busy lately with family visiting, kids, new job, building a house, etc. I haven't had time to update here.
I think this is the pic Ryan was looking for a couple of weeks ago

http://uploads.tapatalk-cdn.com/20160826/a595a91f9957fceefbac0b0a134c2e16.jpg

Omg :drool

[ELCID86]

Sneaky Rob. :foottap


---
"ZHP is a garbage option anyway- just some cosmetic upgrades with a different cam and diff to claw back some of the performance lost fitting those hideous and heavy wheels. Any 330 with a 3.46 diff will smoke a ZHP every time. The whole Mafia thing reeks of childish behavior." - anonymous

[BMWCurves]

You son of a gun.

http://i.imgur.com/lhjhbB9.gif

[Sockethead]

http://uploads.tapatalk-cdn.com/20160827/bcbaf23a57e61c1465eb18299011f32d.jpg

This box arrived the weekend of the kids birthday... It sat in the garage all weekend. It was hard to find the time to get it installed. It took me a couple of weeks to get it all done. On the nights I worked on it, I'd usually start about 9:00 at night after the kids go to bed. How long did it actually take me? Who knows

This is everything in the box, except for my shoes...

http://uploads.tapatalk-cdn.com/20160827/1f852b0cb5e11bbfe61d21588e9ec66e.jpg

http://uploads.tapatalk-cdn.com/20160827/592d2aaa856e3dcc8e377f5d3acf96e5.jpg


It was very complete down to every nut, bolt, clamp and wire... Impressive.

I never realized how much space the intake manifold took up in the engine compartment

http://uploads.tapatalk-cdn.com/20160827/5da1f835c406b094ecb213937921e42e.jpg

Putting in the SC was really difficult because the space wasn't designed for it and that thing is heavy as hell but once it's in, it looks like it belongs there.

[Vas]

Ts1 or ts2?

[BMWCurves]

:drool

Give us a review once you've had some time with it.

[fredo]

I didn't see this coming. Nice ! :thumbsup

[Sockethead]

It's a TS2

http://uploads.tapatalk-cdn.com/20160827/0c9f76a2a0e1fa5682cf79e791d7bbb4.jpg

I'm still trying to find the time to dyno the car to get the tune dialed in. I just finished the 100 mile break in period. It feels pretty strong so far...

[NoVAphotog]

Sneaky...and we were thinking they "didn't have any left"

Guess a trip to Charleston moved up...need to try out one of these. And of course visit you guys... :shifty


Sent from my iPhone 6S using Tapatalk

[Sockethead]

It wasn't supposed to be ready until September. They told me that the Lysholms were gone and the Whipple was still in R&D. I was pretty surprised when they called me two weeks later saying it was ready... I was planning on using that time to sell off some stuff to help pay for the balence... It was more like "Oh shit!"

[Jconlin16]

Awesome stuff. Well done sir!

[rkneeshaw]

I think this is the pic Ryan was looking for a couple of weeks ago

http://uploads.tapatalk-cdn.com/20160826/a595a91f9957fceefbac0b0a134c2e16.jpg

Yup!

That is a beautiful sight to see :)

Once you get it dialed in it is a super fun kit!

[johnrando]

Enjoy it!

Sent from my SM-G935V using Tapatalk

[Sockethead]

Thanks everyone!
I'm just going to post some pics of the process. Ryan (rkneeshaw) covered just about everything you would ever need to know about the install in his TS2 install notes thread. I used his thread as much as I used the installation manual during the install. My installation experience was just about identical to his except they provided the proper hoses to run to the cooler. They've modified some of the parts since they wrote those instructions. That's where Ryan's post is a big help.

Also, thanks to Terraphantm for sending me the stock tune with his M3 cluster mods in it. I had to send that on a flash drive along with my DME so they could overwrite the Dinan tune before putting their tune on

[GotZHP]

Great thread!

I just recently snowballed myself as well. I figured while replacing parts damaged in the accident I should do a few maintenance things. My parts list has gone from $1,350 to exceeding $3,000! I am going after a leaky oil pan gasket since the bumper, carrier, radiator are all off the car. Then I figured since I am replacing the radiator and have already done the water pump, might as well do the rest of the cooling system. Then I noticed the poor condition of the air ducts behind the bumper leading to the brakes. So while replacing those, might as well do all the other plastic trim under the bumper and up in the wheel wells. Figure might as well replace the ambient air temp sensor since it was damaged previously. And while buying sensors, might as well get one for the coolant temp. And since I have to install new headlights, I might as well put them back in with angel eyes. And for shiz n giggles, why not buy a muffler...


when does it end!?

[Sockethead]

You forgot to add headers.... it's SO easy to install them while doing the oil pan gasket... ;)

[holyc0w]

when does it end!?

S54 swap?

[BMWCurves]

http://www.mememaker.net/static/images/memes/4615728.jpg

[theothersawyer]

That is a thing of beauty! I need to do an oil pan gasket as well and I'm not looking forward to it! But if I magically get a supercharger afterwards I may do it sooner!! Haha!

[Karl Lazlo]

Perfect. Simply perfect.

http://www.mememaker.net/static/images/memes/4615728.jpg

[GotZHP]

You forgot to add headers.... it's SO easy to install them while doing the oil pan gasket... ;)

Lol yeah.... Gonna let you know on Monday about that one :cheers

A lot of compulsive buys this weekend already

[GotZHP]

That is a thing of beauty! I need to do an oil pan gasket as well and I'm not looking forward to it! But if I magically get a supercharger afterwards I may do it sooner!! Haha!

I wish I magically got a supercharger too

[GotZHP]

Thanks everyone!
I'm just going to post some pics of the process. Ryan (rkneeshaw) covered just about everything you would ever need to know about the install in his TS2 install notes thread. I used his thread as much as I used the installation manual during the install. My installation experience was just about identical to his except they provided the proper hoses to run to the cooler. They've modified some of the parts since they wrote those instructions. That's where Ryan's post is a big help.

Also, thanks to Terraphantm for sending me the stock tune with his M3 cluster mods in it. I had to send that on a flash drive along with my DME so they could overwrite the Dinan tune before putting their tune on

Do you have any dyno plans in your future?

[Sockethead]

I wish I magically got a supercharger too

Me too! That shit's expensive! :eyetwitch

[Karl Lazlo]

I wish I magically got a supercharger too

Forced Induction by PFM

Pure
Fucking
Magic

[GotZHP]

Me too! That shit's expensive! :eyetwitch

I should have bought a supercharger instead of the stupid plastic bits I bought :facepalm

[san]

Congrats Rob!


Sent from my iPhone using Tapatalk

[az3579]

I should have bought a supercharger instead of the stupid plastic bits I bought :facepalm


Who needs body panels when you can have a supercharger, right? :)

[Sockethead]

It's not like, hey! I think I'll slap a supercharger on my car... although I imagine some people do that. I had to make sure the car was in good mechanical shape. Everything I've done to the car in the last 6 months has been with this in mind... even the M3 cluster with its oil temp gauge. I had to make sure the engine is sealed (gaskets) replaced the fuel filter, already replaced the fuel pump not that many miles ago... replace all of the pulleys and the tensioner, make sure the drivetrain and suspension was in good shape, install headers, check all the hoses, install a catch can, etc. Now I need to get the tune dialed in so I had to buy a datalogger and a boost gauge and I have to get the intake track smoked to check for leaks and there is the time on the dyno. IDK, I just like doing things right...

[Sockethead]

Here's some more pics:
A shot of the water pump looking in with the fog light removed.. Easy access.

http://uploads.tapatalk-cdn.com/20160829/f5bacb38b7187b78a4b2800cf4aa50f1.jpg

The only way you'll know you have a Dinan throttle body... It's not even a stamped BMW part

http://uploads.tapatalk-cdn.com/20160829/58e45e36b85a35336d60c76a973eae90.jpg

A few shots of it on the floor. It's much bigger than it looks when it's in the car. It's heavy too. The box was 90 lbs. The weight of all the parts I took off was 20 lbs so I figure I added about 70 lbs to the front end, give or take...

http://uploads.tapatalk-cdn.com/20160829/fa3669ae0ed3e4891c8fc1b7486b9b56.jpg

http://uploads.tapatalk-cdn.com/20160829/346914fb00ddd194c2061de900464adc.jpg

http://uploads.tapatalk-cdn.com/20160829/e61342845e6ffa224f452676f7a19137.jpg

[Sockethead]

I had a hell of a time getting the intake hose mated to the Dinan Air box. I had to cut off quite a bit
And I had to cut it on an angle. It was a bitch getting that hose onto the idle control valve so there was no way I was going to take the whole hose off and on several times to get it to fit so I used hose clamps and an exacto knife with a new blade. It worked really well.

http://uploads.tapatalk-cdn.com/20160829/41f2015ae89d59045c8cf110862a6a0f.jpg

Getting closer to completion

http://uploads.tapatalk-cdn.com/20160829/423d89e440296dd6089862c858056271.jpg

Another shot of the water pump with the bumper off. They sent wire reinforced PVC hose for the cooling circuit. This stuff is virtually indestructible
http://uploads.tapatalk-cdn.com/20160829/7e48d9ba98a0cba410e64dce04d9ede9.jpg

[Sockethead]

All done!
The kit uses modified s62 injectors which require a spacer on the fuel rail. That's why the cover is so close to the strut bar

http://uploads.tapatalk-cdn.com/20160829/43f316e66b44c9f70d6e0494161c9b0d.jpg



I used a Mishimoto catch can. I was disappointed to find no baffling inside. It is a nice piece though. I welded a bracket together with flat bar from Home Depot.

http://uploads.tapatalk-cdn.com/20160829/685e979b10de222d89972dbc8371ccac.jpg

[BMWCurves]

You could always put some metal sponge in the catch can for a similar, although not exact, effect as baffling.

[holyc0w]

I like the close-up of the throttle body, and the catch can picture.

Surely this engine bay porn can't be legal in all 50 states :thumbsup

[az3579]

I like the close-up of the throttle body, and the catch can picture.

Surely this engine bay porn can't be legal in all 50 states :thumbsup

Well, since breathing itself is illegal in California (let alone any performance modifications), 48- or 49-state legal is probably as good as it gets.

[Hornung418]

Damn, Rob this thread is intense! That Mission creep pic is fucking perfect!

Sent from my Nexus 6P using Tapatalk

[Sockethead]

Yea I guess it is lol. I wasn't planning on everything coming together so quick...

[Hornung418]

Well don't get bored now that it's done! Lol

Sent from my Nexus 6P using Tapatalk

[Sockethead]

It's not quite done yet I still have to get the tune sorted out.... I still need to get it on the dyno to get the AFR dialed in but I may wait until sometime in September since it's been so hot and humid here. Also, I'm trying to figure out a rough startup/idle issue and one of the ESS idler pulleys is squealing like a pig so I'm waiting for the replacement. I got to drive for the 100 mile break in but now it's just sitting waiting for the pulley. It's squealing bad enough that I'm afraid it might seize up...

[Hornung418]

Oh yeah that was like 5 pages back LOL! Well how did it feel with an extra 100 hp? Have you had a drag with Kpro yet?

Sent from my Nexus 6P using Tapatalk

[Sockethead]

IDK, I've had a chance to open it up a couple of times. I definitely doesn't have the hit of the 135's turbos and her car still puts out over 100 more HP... It does have a lot more torque than stock and it comes on really early... Once I get the tune dialed in I'll definitely have to race her... just because :)

[Hornung418]

Can't wait to visit when I'm all done with the 951. Well have a boosted drag race.

Sent from my Nexus 6P using Tapatalk

[Sockethead]

Lol come on down! Hopefully we'll be in our new house by then :thumbsup

[GotZHP]

Hey, currently doing my oil pan gasket as I type. Did you follow a DIY guide? If so could you forward the link to me please.

[Sockethead]

I didn't have a DIY. Vas gave me a few tips like don't uncouple the steering. There are a bunch of YouTube videos too. I might of mentioned a few tips at the beginning of this thread...
Some of the bolts in the back of the oil pan are pretty tricky to see and two them go up in the bell housing. There was one that I missed and I couldn't figure out why the pan wasn't coming off.
Only use a rubber mallet to break the pan free. Resist the temptation to pry it off.

[Karl Lazlo]

Hey, currently doing my oil pan gasket as I type. Did you follow a DIY guide? If so could you forward the link to me please.

Evidently, the DIY for Sockethead's pan gasket replacement starts here... https://www.ecstuning.com/BMW-E46-330Ci-M54_3.0L/Engine/Supercharger/

[Sockethead]

Lol actually here: http://esstuning.com/m54b30-twin-screw-stage-2-ts2/

ECS only has centrifugal... Not worth it IMO

[Karl Lazlo]

I stand corrected.

[danewilson77]

Well done Rob. Awesome work.

S7 Edge, out

[Sockethead]

Thanks Dane! I'll be happy when it's finally sorted out and dialed in ;)
It's been a lot of work and late nights working around the kid's schedule but I like a good project

[Karl Lazlo]

It has been stuck in my head since I read your thread title. I have been reading it in John McClane's voice.

https://www.youtube.com/watch?v=dMQdqO4RV3w

[Sockethead]

hahaha ! It does sound like that, doesn't it...

[Karl Lazlo]

hahaha ! It does sound like that, doesn't it...

If in your on-going projects, if you find an MP5 or AUG as you do vehicle maint, let me know.

"Ho Ho Ho. Now I have a machinegun."

[GotZHP]

Evidently, the DIY for Sockethead's pan gasket replacement starts here... https://www.ecstuning.com/BMW-E46-330Ci-M54_3.0L/Engine/Supercharger/

LOL

[rkneeshaw]

I had a hell of a time getting the intake hose mated to the Dinan Air box. I had to cut off quite a bit
And I had to cut it on an angle. It was a bitch getting that hose onto the idle control valve so there was no way I was going to take the whole hose off and on several times to get it to fit so I used hose clamps and an exacto knife with a new blade. It worked really well.

http://uploads.tapatalk-cdn.com/20160829/41f2015ae89d59045c8cf110862a6a0f.jpg

Brilliant! I wish I had thought of that. My cut wasn't very straight :( With the BMW Performance intake I had to cut it at a slight angle too in order for it to mate up properly.

[rkneeshaw]

IDK, I've had a chance to open it up a couple of times. I definitely doesn't have the hit of the 135's turbos and her car still puts out over 100 more HP... It does have a lot more torque than stock and it comes on really early... Once I get the tune dialed in I'll definitely have to race her... just because :)

If those AFR's are as rich as mine were out-of-the-box then it will really come alive when they get dialed in.

And once you get our tune dialed in and drive it a bit, you'll start looking into a smaller pulley, then maybe FI cams, then meth injection, etc :) :)

[Sockethead]

oh gawd, I hope not... ok well maybe an 83mm pulley...

[Sockethead]

Brilliant! I wish I had thought of that. My cut wasn't very straight :( With the BMW Performance intake I had to cut it at a slight angle too in order for it to mate up properly.
I remember you saying how hard it was to cut it strait and square and just started thinking about what I could use...

[GotZHP]

Man, I am going to need to buy a Supercharger to get over the trauma caused by this oil pan gasket..... Worst thing I have ever done on a vehicle and I've worked on everything from a 1952 Jeep M38A1 to a 2014 Subaru BRZ.

I certainly would be a lot more motivated to finish this if I had boost on start up :D

[Sockethead]

Installing the TS2 is just as much if not more work than the oil pan gasket but at least you're not laying under the car for long periods of time... and the end result is a little more satisfying :)

[Vas]

I was not too annoyed with the oil pan gasket. It goes back together alot faster then removing all the stuff to get to it. And at the end, no more leaks.

[Sockethead]

I didn't think it was that bad either...

[az3579]

I was not too annoyed with the oil pan gasket. It goes back together alot faster then removing all the stuff to get to it. And at the end, no more leaks.
But you DIY eeeeeeeeverything so it would take more than that to phase you. :)

Sent from my VS990 using Tapatalk

[Vas]

But you DIY eeeeeeeeverything so it would take more than that to phase you. :)

Sent from my VS990 using Tapatalk

If i was not able to DIY, i would be probably be driving a manual tsx.

[Sockethead]

But you DIY eeeeeeeeverything so it would take more than that to phase you. :)

That's a good point I never thought about...

[Sockethead]

I found a loose hose clamp on the intercooler last night. Unfortunately, it introduced enough air into the system that it's impossible to get it out using the method in the ESS instructions. I'm going to have get creative to figure out how to purge it... And quick, I have a dyno appointment tomorrow morning.
I'm hoping that between purging the intercooler system and getting the tune dialed in, they'll both fix the lack of power the car has right now. I had it smoke tested earlier in the week and there are no vacuum leaks...

[Sockethead]

After spending three hours trying to purge the intercooler of air, I gave up for the night. ESS instructions say to pull the top hose off and manually fill the 5/8 hose with antifreeze until it drips out the fitting on the manifold. This method relies on gravity to purge the air out and, as we all know from our cooling systems, this can be a bitch even with a bleeder and an expansion tank.
I thought about it in bed last night and the solution is so simple I'm surprised I didn't think of it sooner. Got the intercooler purged in less than 5 minutes by getting some couplings and extending the return line using two hoses into a small bucket of antifreeze. The air in the return line could escape in the bucket while the suction sucked in all antifreeze.

Here it is in action:

https://vimeo.com/182184408

This is after all the air was purged out...

https://vimeo.com/182184571


I think I'm going to look for a compact expansion tank I can put in the drug box along side the catch can. That way I can always be sure the air is out and the intercooler has plenty of fluid.

[ELCID86]

Nice job figuring that out Rob. Dyno results??


---
"ZHP is a garbage option anyway- just some cosmetic upgrades with a different cam and diff to claw back some of the performance lost fitting those hideous and heavy wheels. Any 330 with a 3.46 diff will smoke a ZHP every time. The whole Mafia thing reeks of childish behavior." - anonymous

[GotZHP]

Nice job figuring that out Rob. Dyno results??


---
"ZHP is a garbage option anyway- just some cosmetic upgrades with a different cam and diff to claw back some of the performance lost fitting those hideous and heavy wheels. Any 330 with a 3.46 diff will smoke a ZHP every time. The whole Mafia thing reeks of childish behavior." - anonymous

+1 :thumbsup

[Sockethead]

I have the dyno results and they are disappointing. 288 HP was the best it could muster. AFR is almost spot on. Granted it was 89 degrees but I was hoping for at least 300 HP to start with. I had 8.5 lbs of boost at 6800 RPMS which is a tad low. I ran a data logger on all three runs as well. Timing looks good.
IDK... We'll see what the ESS tuner comes back with.
I also developed a header gasket leak on the front header during the dyno run... Bummer.

http://uploads.tapatalk-cdn.com/20160911/66dd716f09eabdcfef1e9127c863940f.jpg

[rkneeshaw]

Hang in there sockethead, in my experience it takes a little tweaking to get things dialed in with this kit, but well worth it in the end!

My problem is I can never get satisfied enough. I get things tweaked nicely, and the car running great, but then I want to add cams, or I want to add methanol injection, or I want a smaller pulley.. etc etc etc :)

[Vas]

Are the numbers lower then they advertise ?

[Sockethead]

They advertise 355 hp SAE on a ZHP...

[GotZHP]

They advertise 355 hp SAE on a ZHP...

Dman, so there is more left on the table for sure.

What's your elevation?

Gasket leak on the exhaust side of things is bad too because you won't be getting the full effects of exhaust scavenging.

what is the boost suppose to be at? 9PSI ? or higher?

Also, how were the fuel trims this time around?

[ELCID86]

He's in Charleston SC, about as close to sea level as one can get ! Hope the tuner can get more power!!


---
"ZHP is a garbage option anyway- just some cosmetic upgrades with a different cam and diff to claw back some of the performance lost fitting those hideous and heavy wheels. Any 330 with a 3.46 diff will smoke a ZHP every time. The whole Mafia thing reeks of childish behavior." - anonymous

[rkneeshaw]

15% drivetrain loss on 335hp = about 285whp.

But that's for a stock ZHP, and sockethead has some mods that should add more power.

The 89 degree heat didn't help, but I think his boost seems low. I think it should be 9 to 10 psi when measured before the intercooler cores.

I wonder if that exhaust leak is contributing in some way

[GotZHP]

Hmm, 89 degrees is higher than desired but not really high heat. the exhaust leak is def robbing power. I also think there needs to be more tuning to be done.

[Sockethead]

They call this part of SC "The Low Country" we're at sea level.
I haven't been here that long but it's been in the high 80s and 90s since June. We had a lot of days right around 100 this summer.
The exhaust leak sounds like just 1 cylinder. I'm not looking forward to fixing that.
I sent all the data logs and dyno results to ESS. We'll see what they come back with. They are in Norway so there's a pretty big time difference. I'm not driving the car until I get the header leak fixed.
I'm hoping I can get it all sorted out before the meet so you guys that are going can see it and test drive it at its full potential...

[GotZHP]

Well hope it all works out.

Headers seem like a bear on this car. Going to be doing that to my car soon :D

[Sockethead]

Yea they are a bitch...at least the bimmerbrakes Gen3 headers. Other ones that don't twist all over the place will be easier.
IMO they are really worth it. As I keep saying, they make a huge, very noticeable difference in torque...

[Sockethead]

Well, it looks like they gave me the wrong injectors... the tune is calibrated for "the red injectors" and I got white. I also found out that they didn't wipe the Dinan tune with the modified OEM file from Terraphantm. They installed their calibration on top of the Dinan file which I'm not too happy about but the dyno run looked pretty good albeit down on power from where I thought it should be. They are overnighting the injectors. I haven't had a chance to check for the exhaust leak yet I have to get another dyno run in after the injectors are installed... this is getting expensive at $85 for the dyno. We shall see if I can get it sorted out before the meet...

[BMWCurves]

Hopefully those two issues are the culprit.

[san]

Hopefully those two issues are the culprit.

+1


Sent from my iPhone using Tapatalk

[Sockethead]

I found the leak in the front header. Nothing wrong with the gasket. Looks like they tacked the pipes together for welding during production and the tack weld fully penetrated the pipe then broke out once they've been run on the car for a while. I used a mirror to take the picture. You can clearly see the hole in the middle of it

http://uploads.tapatalk-cdn.com/20160915/6650c6467e3bda811682892298deb66f.jpg

I'm not too happy about because I'm going to have to pull the header out of there which is going to be a huge PITA. I have to take out the engine mount, etc plus buy a new gasket which is like $36

[rkneeshaw]

Dang, thats annoying. You going to try to get that header repaired or are you going to have to get a fresh set?

[Sockethead]

IDK, I have less than 500 miles on the set. I contacted the place where I got them but I'm not holding my breath for an answer. No matter what, The front one has to come out. I'll probably just have it welded.I can't do it myself because my MIG welder isn't setup for stainless steel...

[Sockethead]

New injectors ready to go in. We'll see what these do...

http://uploads.tapatalk-cdn.com/20160916/be589323a4e91c3a69e89300c92ec6de.jpg

[ELCID86]

That sucks Rob. I hope they admit the design/build flaw and help you out.

[rkneeshaw]

New injectors ready to go in. We'll see what these do...

http://uploads.tapatalk-cdn.com/20160916/be589323a4e91c3a69e89300c92ec6de.jpg

I recognize those! I hope that helps.

[Sockethead]

http://uploads.tapatalk-cdn.com/20160917/eb785c97033cbbe56c9abc167ec8fb38.jpg

New injectors installed. I buttoned everything up and took it for a spin. It took a bit for idle to even out but it felt pretty good. 75° outside. 14° cooler than it was during the last dyno run. I have another dyno run scheduled for tomorrow morning..,

[Sockethead]

I couldn't do the dyno this morning. They said the exhaust leak will skew the AFR. Now I have to pull the header and get that TIG welded and get it back in sometime this week so I can get it back on the dyno. I found a highly skilled TIG welder at a shop a few steps away from the shop with the dyno.

Here's some of their work:

http://uploads.tapatalk-cdn.com/20160917/c6f51836eaf3940d2eeeac44cdf52952.jpg

http://uploads.tapatalk-cdn.com/20160917/ca8189c97568112b059ae8507a4495e5.jpg

When I first came down here I was wondering how I was going to find all new people for various projects. I had a great network in Jersey and VAC was just over the bridge.
In the last few months I've met a great group of people here in Charleston that are highly skilled and very friendly. I'm very happy about that...
Now I'm off to remove half the front end to get that stinkin header out!

[ELCID86]

Good luck. I know your up to the challenge.

Glad you like it there. One of my favorite places. Can't wait for our trips down on Oct and Nov.

[Sockethead]

If you have some free time while you're down here, lets get together...

[ELCID86]

If you have some free time while you're down here, lets get together...

Would love to, but doubtful. Oct is Parent's weekend with the seniors getting heir rings, football game and showing our German exchange student around. Nov is my 30th reunion with lots of activities ...

[rkneeshaw]

looking good dude, glad you've tapped into the local car network there, that can make a big difference.

Best of luck on that header. It should go ok now that you've done that job before. If you removed that SAP you'll have more room from up top too.

[Sockethead]

It's frustrating having to deal with the header on top of trying to get the tune sorted out...

You know, every shop I've been in down here has had incredible cars from every discipline but I never see them on the road. I have to find out where they are all hanging out.

[GotZHP]

It's frustrating having to deal with the header on top of trying to get the tune sorted out...

You know, every shop I've been in down here has had incredible cars from every discipline but I never see them on the road. I have to find out where they are all hanging out.

Dude same in my area! I just found a BMW specialty shop / race team a block from my work. They have a E46 M3 that they moved the motor rearwards by 10"s and put a dry sump where the passenger use to sit. I've never see any BMWs by my work ever. HillBank (Mustang guys) are right around the corner, but you see and hear their cars all the time.

Hope the header works out.

[Sockethead]

Thanks, the headers will work out. It's all the labor that I'm not looking forward to.

I can't believe I'm here again...

http://uploads.tapatalk-cdn.com/20160920/86b7a07ccafa1fdbccbf19ece0bc5bdd.jpg

[Sockethead]

It's out.

http://uploads.tapatalk-cdn.com/20160920/e9a6f2fcc67c46d13c892fce61dad5ad.jpg

http://uploads.tapatalk-cdn.com/20160920/debfdfe14a49c4a7930662a5b37addce.jpg


I hope they can plug weld that without joining the pipes together again...

[GotZHP]

It's out.

http://uploads.tapatalk-cdn.com/20160920/debfdfe14a49c4a7930662a5b37addce.jpg

I hope they can plug weld that without joining the pipes together again...

Well that's a problem right there!

Why / what caused the hole??

[GotZHP]

Thanks, the headers will work out. It's all the labor that I'm not looking forward to.

I can't believe I'm here again...

http://uploads.tapatalk-cdn.com/20160920/86b7a07ccafa1fdbccbf19ece0bc5bdd.jpg

Wait, you have to remove motor mounts to get the header out?!? That red bar is awfully familiar (Just did my oil pan gasket)

[Sockethead]

Yep, I had to remove the right motor mount bracket to slide the header out. At least it was the front one so I can leave the rear one in place. It wasn't too bad getting it off...

The hole is because they tack welded the two pipes together during assembly and didn't grind it out later. I saw that when I went to put them in wondering if it would end up being an issue....it didn't look like it really penetrated the pipe but it did. You can't have a weld like that between the pipes, too much movement and vibration

[GotZHP]

Yep, I had to remove the right motor mount bracket to slide the header out. At least it was the front one so I can leave the rear one in place. It wasn't too bad getting it off...

The hole is because they tack welded the two pipes together during assembly and didn't grind it out later. I saw that when I went to put them in wondering if it would end up being an issue....it didn't look like it really penetrated the pipe but it did. You can't have a weld like that between the pipes, too much movement and vibration

Movement, vibration, AND heat. That leads to broken parts. Did you buy the headers used or new? I would shoot an email to BimmerBrakes and be like yo, this aint good.

I was going to pick up some headers, but seems like a lot of work to get them in. PLus I gotta worry about SMOG at the moment. I think I need all new O2 sensors.

Can the )2 sensors be accessed with having to remove headers?

[slater]

that sucks, rob. but, i feel like we get dealt things we can handle. and you're a guy who can handle this! so i hope everything comes around for ya in the end! the car will be much sweeter when it's all sorted out. :cheers

[Sockethead]

No matter how much work it is, the headers are still worth it. The O2 sensors are accessible without removing the headers. I left it in then removed it once I had it out. I used copper based antisieze on the threads so my O2 sensors come out real easy.

Thanks Peter, I'm trying to look forward to the end result. It's just hard with everything going on. I really want to make it to the meet this year and it looks like it's going to come down to the wire with this car

[slater]

No matter how much work it is, the headers are still worth it. The O2 sensors are accessible without removing the headers. I left it in then removed it once I had it out. I used copper based antisieze on the threads so my O2 sensors come out real easy.

Thanks Peter, I'm trying to look forward to the end result. It's just hard with everything going on. I really want to make it to the meet this year and it looks like it's going to come down to the wire with this car

...sometimes that's how it is. :)

what are you doing for the CEL situation with the headers? i've been wanting to do headers, and i have a used set of bimmerbrake headers here, but i've been looking at the schmiedmann ones with the cats just below the header exit.

[san]

...sometimes that's how it is. :)

what are you doing for the CEL situation with the headers? i've been wanting to do headers, and i have a used set of bimmerbrake headers here, but i've been looking at the schmiedmann ones with the cats just below the header exit.

Terra coded the CEL off I think...


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[Sockethead]

I had the post cat sensors and the SAP coded out... Terraphantm did it for me as a favor when he had my DME for the M3 cluster mod. Then when I sent the DME to ESS, they coded it out too after installing their software

[Sockethead]

I got the header back in and everything buttoned up last night. It was much easier than I anticipated. I installed all the nuts except for one from the bottom. It was much easier that way. It took 2 hrs from start to finish to get the header back in. Now I can get back to the dyno.
The guy that welded the header for me was really a good guy. He even stopped at my work to pick it up on his way in. He was going to do it for free but I couldn't take advantage like that so I gave him a $20 for his troubles. Turns out that have a bunch of bimmers in their shop including an e30 M3 in the middle of a full restore.

Anybody doing these headers, get yourself a fine toothed ratcheting combination wrench with the box end offset like this one:

http://uploads.tapatalk-cdn.com/20160922/b440769aa48b16d5d390c37478d3c0af.jpg

This wrench will be your best friend for the nuts in the middle.

Anybody installing these headers and need some tips let me know and I'll give you a run down on what you need to remove and how to get to the nuts. Always use new studs and nuts. The cost outweighs the ease of header installation with new hardware.

[san]

Glad you got it done without too much of a hassle... looking forward to the dyno results!


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[BMWCurves]

Glad you got it done without too much of a hassle... looking forward to the dyno results!


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+1

[johnrando]

+1

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[Vas]

Awesome sauce

[Sockethead]

The dyno run with the red injectors was so lean that the car almost over heated on the first run. I'm not too happy right now...
Sent the graph to ESS.

http://uploads.tapatalk-cdn.com/20160923/89c5e6be5c5d01e385709accf2809124.jpg

[Johnmadd]

Oh no! What next?

[Sockethead]

More tuning...

[Vas]

Based on the previous vs new graph, you were better off with the white injectors. At least the car was not running lean all across the board.

Car is begging for more fuel

[Sockethead]

Yea, Lets see what they say about that...

[Sockethead]

Not much progress on the car. I haven't really touched it since hurricane Matthew. AJ at ESS insisted that they install their full tune instead of the Frankenstein tune they did on top of the Dinan tune so I lost the warm up lights on the M3 cluster. When I started the car the CEL came on. They forgot to code out the SAP. Got that fixed but I just haven't had the time or motivation lately to test the car: I have to either spend another $85 for a dyno run or do a run on the highway in fourth or fifth gear and run my datalogger to get the AFR. I really don't want to do 100+ on the highway to get the proper load on the motor.
Also I've been trying to track down a weird noise the supercharger is making on cold startup. No one can figure it out. I've listened extensively with a stethoscope but the noise seems to be in the entire intake track from the throttle body to the supercharger scroll housing. Hans offered to send me anther unit but I need to be sure that the SC is source of the noise before I swap it out. It doesn't seem to be affecting the performance but it makes my car sound like a POS. Hopefully I'll get a chance to work on it this weekend.

https://vimeo.com/191236830

[Sockethead]

I finally have an update. After working with AJ at ESS we've finally gotten the AFR close to were it should be. Although I'd like to see it a little richer below 5000 RPMs and a little more timing advance. For the first time since I installed it. The car finally feels like it has a supercharger on it.

http://uploads.tapatalk-cdn.com/20161128/5f7ce609850f838be4f55cb1e85d3901.jpg

Getting AJ at ESS to read my data log spreadsheet and follow what I'm trying to tell him has been a very frustrating process. He wants a dyno run with AFR for every little change and seems to be too set in his ways to think outside the box... Multiple dyno runs are too damn expensive at $100 a shot. I can collect so much more useful data than just a HP rating and an AFR out the tailpipe than a Dynograph can give.

[Vas]

Maybe worth considering a wideband o2 sensor that can datalog data? Then send that data to them?

[Sockethead]

The problem isn't the data, the problem is getting him to read all the data I'm sending him and tune accordingly. Both Ryan and I are beginning to think that they don't really know how to tune an MS45

If you look closely at the image of the spreadsheet I posted, you can see the name at the top of each column... This is about an 1/8 of the data I can collect from the DME using the datalogger.

[Sockethead]

The latest tune is getting close! The car is much more responsive. When I nail the gas in first gear and have the tires break loose... This is with a 3.15 LSD, pretty impressive. Low speed power slides around turns is possible with a blip of the throttle. The tune still needs more work, still running lean in the lower RPMs and the timing is all over the place as seen in the second graph in the pic below. I have another update from AJ but I won't be able to test until next week as the wife is out of town, so the twins come first.

http://uploads.tapatalk-cdn.com/20161202/77b7282cae6e23e0b0d298001f1fbb42.jpg

[san]

Must be really frustrating that it's taking so long, but glad you are getting closer...


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[slater]

good stuff, rob! glad you're making headway with the tuning!! :)

[NoVAphotog]

Low speed power slides around turns is possible with a blip of throttle...

My next visit to Charleston could be dangerous for the wallet...

[Sockethead]

You know, with all the issues I was having, I was really kinda regretting the purchase but I also wanted to give it a chance.... I'm starting to like it now.
Ryan (rkneeshaw) said it would be like that...

Daniel, we'll have a real spare bedroom next spring when our house is done... come on down with your girl!

[johnrando]

Good to hear

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[Sockethead]

It's been a while since I've had anything to update and I've been busy with the kids. I've gotten, I think, two more tunes and I got it dyno'd. The car feels really good but it's still down on HP for some reason. However, the torque curve looks great. From a rolling start in 1st gear the car pulls hard.

http://i424.photobucket.com/albums/pp325/r_powell123/62EFE6CD-AF96-4CC5-928D-0C90308C911A_zps6dnphxg2.jpg

As you can see from the chart, the torque comes on really early and stays pretty much flat until redline (self imposed at 6500 rpm) The HP is flattening out around 5800rpm or so but I'm not sure why. AFR looks pretty good although I'd like to see it around 13 or lower. I think I may have a boost leak since I only got 8.5 psi at 6500rpm. I should be getting 9.5 by then and I even went to a smaller pulley.

So my immediate list is:
Look for a leak some where.
Replace the oil level sensor to get rid of my check engine light.
Replace the ICV to hopefully fix some idle issues.

All of this will require removing a lot of stuff and laying under the car. Unfortunately, I injured my back a few weeks ago and I've been in extreme pain. I can't walk more than a dozen feet and even that is extremely painful. I bought a wheelchair last weekend and I've been rockin' that to get around the house, work and shopping. It's been a real challenge to do anything and since I don't have a handicap card, I still have to park where ever. Funny thing is when I'm sitting I have no pain at all and I can still drive my car without issue.

I'm hoping that between all the drugs the Dr's are giving me and PT, I'll be back in action soon but for now this is my ride. I stripped off the foot rests and the arm rests, lubed and adjusted the bearings, It goes pretty good now

http://i424.photobucket.com/albums/pp325/r_powell123/CACCF187-9548-4EDB-B528-51C6F8DCC467_zpsqjqwgxis.jpg

[Vas]

Hope you get better. Back problems suck since I suffer from them as well.

[danewilson77]

Sorry to hear Rob. Could always be worse. One of my operators at my plant had his right leg surgically amputated about 10" above the knee due to diabetes yesterday.

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[3ZHP]

Hoping for a quick recovery for you. Sucs to be down with the great weather in February. [emoji856]


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[Sockethead]

Yea there is always someone with a worse problem. I'm pretty upbeat about it. I'm just looking forward to getting my car done and playing with the kids again

To be honest, I rather talk about my car than my back :)

[Karl Lazlo]

To honest, I rather talk about my car than my back :)

Yeah, that's the right attitude. But, I have to ask, what wheels are on that chair and what is the offset? They are bitchin'!

[slater]

sorry to hear about your back issues, rob. any idea what caused it? i assume it's lower back pain? nice that you can sit/drive/wheelchair without pain. at least you've got some relief.

back pain sucks. hope you're up and around soon! :cheers

[rkneeshaw]

Nice update Rob, but sorry to hear about the back problems :(

A leak between the compressor and the motor would cause low boost readings and a rich condition.

A leak between the MAF and the compressor would cause a lean condition but boost would be on-par.

Could the whipple compress differently from the Lysholm, and maybe should have a smaller pulley to reach the same levels of boost?

Puzzling facts:
You're still on the lean side of things
You have low boost

Those two things are like opposite ends of the spectrum. If you are lean I'd expect too much boost, but you have low boost. If you have low boost I'd expect you to be running rich, but you're still leaning lean.

That all assumes the tune is dialed in right too. I wish I knew what AJ was up to when he adjusts our tunes. My car got really rich when I added the M3 fuel pump, and AJ had to keep making adjustments to lean out my tune to compensate. In your case, its the opposite, you're real lean and AJ has to keep adding fuel.

I'm very disappointed in ESS' tunes for the MS45. I'm sure they dyno tuned the hell out of their MS43 tune but I truly believe they then thought they could just map it over to the MS45, not realizing the MS45 is a much advanced DME. And from what I gather tuning the MS45 requires different strategies compared to the MS43. Personally I feel my throttle is too sensitive (its ON/OFF which makes it hard to be precise with the throttle when hooning around). I'm so ready to go get a custom dyno tune from TTFS or Nick G. I think the hardware in these kits is great, but at this point I feel the tuning sucks.

[Sockethead]

Yeah, that's the right attitude. But, I have to ask, what wheels are on that chair and what is the offset? They are bitchin'!



Well I had to adjust them. They had a little too much negative camber and it was pulling to the right

[Sockethead]

I hate the way TappaTalk doesn't always update the individual threads... I missed all the posts after Mr. Laslo....

Peter you're going to laugh... it all started when I tried to intercept a sandwich one of the twins was throwing on the floor. I pulled a muscle on the right side between my back and butt. It just went downhill after that.
I think it's the sacroiliac joint in the hip as my symptoms are different than a bulged disk even though the MRI shows a slight bulge. I've had disk problems before and this doesn't feel the same. In PT, my symptoms weren't getting any better with traditional spine therapy and my pain patterns weren't like that of a spine injury. She switched to therapy for the Si joint and that has helped after one session... keeping my fingers crossed that I will be out of the wheelchair in the next few weeks.

Ryan, I just haven't had a chance to get in there and really look. It's weird that I've always been running lean. I wonder if the belt is slipping? I used the same belt for the 83mm that I used for the 85mm pulley. I figured it wouldn't be that much of a difference but I was getting 9.5lbs of boost with the 85mm...

I agree with you as far as AJ goes. He is a man of few words... Last tune I asked him not to touch the timing, just give me more fuel to see if that stabilizes the timing. I haven't checked side by side yet but I swear it's got less timing on this tune

[Sockethead]

I'm going to smoke test the car this weekend. Shawn was nice enough to bring along his smoker on his trip to Charleston for family matters. Hopefully he'll have enough time to take my car for a spin when we meet up. he's got a pretty full schedule....

My back is much better. I haven't used the wheel chair in a week. I'm still in a lot of pain but it's manageable so I'm going to start working on the car again.. yay!

I was quite embarrassed yesterday when this guy in a riced up Civic wanted to race at a traffic light... when I shifted into 2nd, the car fell flat on its face due to DSC kicking and killing the throttle. They guy pulled ahead of me for a bit until the throttle came back on then I easily walked away from him. He gave me the righteous nod that he had been beat but I have to do the M3 programming to stop that annoying DSC behavior.

[Sockethead]

Going to cars and coffee with the boys. They are so excited! ;)https://uploads.tapatalk-cdn.com/20170311/7906b95485838a562e156a2043592b7c.jpg

[WOLFN8TR]

Cute kids. They sure are getting big! My daughter turned 6 on Thursday.

[fredo]

+1. That seat would look very nice on my IR/black. My boy turned 6 y/o seven weeks ago.

[ELCID86]

Great seeing you today Rob and I enjoyed experiencing your increased HP! Car looks and drive amazing.

[Sockethead]

Thanks Shawn, good seeing too. You car is sweet. Can't wait to use the smoker and put the intake track leak question to rest.

[Sockethead]

Cute kids. They sure are getting big! My daughter turned 6 on Thursday.

Thanks! Actually they are a little small for their age but who cares... I love my little guys!


+1. That seat would look very nice on my IR/black. My boy turned 6 y/o seven weeks ago.

Those seats are Recaros. Kristen had to have them-they are really nice though and pretty easy to handle.

Congrats both of you on your kids's birthdays!

[Sockethead]

So I was in my way to cars and coffee yesterday and this happened
https://uploads.tapatalk-cdn.com/20170312/f49e5df5ddca0b53287dad0ef6ea9636.jpg
The cracks are spreading rapidly down the windshield

No worries though, in South Carolina, the insurance companies can't charge against you deductible or have it go against your record so basically, I get a free windshield.
I'm not too upset about it because my windshield is really sand blasted after 141k miles

[danewilson77]

I don't understand what happens to E46 with windshields vice other models. I've never owned another car that this happens to. Guess it must be the lower profile. Every E46 I've owned ends up having the sandblast effect.

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[derbo]

So I was in my way to cars and coffee yesterday and this happened
https://uploads.tapatalk-cdn.com/20170312/f49e5df5ddca0b53287dad0ef6ea9636.jpg
The cracks are spreading rapidly down the windshield

No worries though, in South Carolina, the insurance companies can't charge against you deductible or have it go against your record so basically, I get a free windshield.
I'm not too upset about it because my windshield is really sand blasted after 141k miles

I've been waiting for this to happen since I've owned the car. My windshield is pitted like pollen got dusted over it and the clarity is bad during certain conditions where the sun just Fs it up.

[Sockethead]

Yep that's mine too. Almost glad this happened

Now the problem is trying to get decent glass out of the insurance company. They only want to pay for cheap Chinese glass, which according to my wife, doesn't fit correctly and is causing the A pillars to rust out.
According to her, the OEM glass is like $1k more than the cheap glass so I'm hoping to find something decent in between.

[ZHPizza]

Yep that's mine too. Almost glad this happened

Now the problem is trying to get decent glass out of the insurance company. They only want to pay for cheap Chinese glass, which according to my wife, doesn't fit correctly and is causing the A pillars to rust out.
According to her, the OEM glass is like $1k more than the cheap glass so I'm hoping to find something decent in between.

Do you have the rain light sensor? I got my non-RLS windshield replaced with the correct Pilkington glass from an independent guy for about the same price as the garbage from Safelite.

EDIT: Just looked at my records and it was $300 installed for the Pilkington glass in an non-RLS sedan.

[san]

Kinda hard to believe that insurance companies get away with this.


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[Sockethead]

Do you have the rain light sensor? I got my non-RLS windshield replaced with the correct Pilkington glass from an independent guy for about the same price as the garbage from Safelite.

I'm my wife is trying to get the Pilkington glass... We'll see what happens.

[az3579]

Yep that's mine too. Almost glad this happened

Now the problem is trying to get decent glass out of the insurance company. They only want to pay for cheap Chinese glass, which according to my wife, doesn't fit correctly and is causing the A pillars to rust out.
According to her, the OEM glass is like $1k more than the cheap glass so I'm hoping to find something decent in between.


Safelite said an OE glass for my car was in the $500's from the local dealer. It shouldn't be costing you anywhere near $1k...

[Sockethead]

I thought I remembered you saying that I'll have run that by her tonight...

[Hornung418]

Love it! Gosh they're getting so big! Can't wait to see them soon!

Sent from my Nexus 6P using Tapatalk

[ELCID86]

I got Pilkington from a local shop for <$325 otd. Always check the RLS before you leave the shop (spray mist on it...)!

[Sockethead]

Safelite said an OE glass for my car was in the $500's from the local dealer. It shouldn't be costing you anywhere near $1k...

I asked her and she said the price was over 1K direct from BMW. I wonder if she is thinking of another BMW or the price has gone up that much...




Love it! Gosh they're getting so big! Can't wait to see them soon!


Come on down!


I got Pilkington from a local shop for <$325 otd. Always check the RLS before you leave the shop (spray mist on it...)!

Pilkington it is. That's what she ordered. I'll make sure she tests it before she leaves the dealership... good advise!

[az3579]

Just keep in mind that not all Pilkington is the same. There are some sub-brands of Pilkinton that are of crappy quality. I specifically ordered Pilkington when I had mine damaged and they ordered another sub-brand of Pilkington. I made a fuss about it and they ended up ordering me a Genuine BMW glass, which is also Pilkington.

[Sockethead]

Ugh, replacing windshield shouldn't be so hard... Damn all this cheap crap!

[rkneeshaw]

Glad your back is doing better!

Sorry to hear about the windshield, glad you're getting it sorted though, and you're on the right track. I made the mistake of taking the windshield safelite gave me, and its wavy. Annoys the crap outta me. They gave me the option to get the official BMW glass for like $300 more, I regret not doing that!

[Sockethead]

It's Pilkington DOT177. From what I can tell, it's either Mexico or Cleveland

[Vas]

The windshield on Sketchi is also beat to hell. Just have not replaced it yet because of now knowing what will be installed.

[Sockethead]

The DOT number in the corner of the glass is the key. I started a thread about it a while ago and BP is very knowledgeable on the subject.

EDIT: Found it: http://www.zhpmafia.com/forums/showthread.php?16717-e46-glass-What-to-look-for

[Sockethead]

I emptied my catch can for the first time since installing it last September. It was half full... of water! There was no oil in it whatsoever. WTF?
I was skeptical even putting it in since there was no baffling in it but went ahead anyway to see what would happen... now I know. If there is no baffling, don't even open the package, just return it because it's completely useless unless you want to condense water.

On the other hand, I guess I don't have much blow by either.... not bad for 143K miles. I'm just going to eliminate it all together.

https://uploads.tapatalk-cdn.com/20170415/365d156c33b829b78df3e52c154023b7.jpg

[cakM3]

Strange since your setup looks solid Rob.....


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[ELCID86]

So the design is flawed or unit is faulty/missing components?

[Sockethead]

IDK.... I'm thinking that maybe there is an air leak...perhaps the valve cover gasket, that's pulling a lot of air in. The catch can is in the drug box and it's cooler in there so the catch can turns into a little distillery and the water condenses out...

Last time the valve cove gasket was replaced was by the dealer when the car was still under factory warranty.... that was about 100k ago and 2009 so I'm gonna start there.

[san]

Damn that's strange! [emoji15]


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[Sockethead]

Yes very strange. If anyone else has a theory, I'd like to hear it.

[Zhpabe89]

Damn Rob , you are a trooper. You have literally had the worst of luck with this TS2 kit. Hope you figure it out soon so you can enjoy the car. I really hope that I put down 300+. If not I’ll be pissed for spending 9k.

[Sockethead]

It wasn't all bad...I think Ryan has had it worse than me but he's got it pretty much sorted out at this point. Here's his project thread if you haven't run across it yet... http://www.zhpmafia.com/forums/showthread.php?16665-The-life-of-Ryan-s-2003-ZHP

[Sockethead]

Been a long time since I updated here, I did get some work done last spring but life and getting the M2 kinda took over...
I got the drive shaft rebuilt with a new guibo, center bearing and guide bearing. New front and rear Diff bushings and new adjustable lower control arms and bushings.

https://uploads.tapatalk-cdn.com/20180828/b1da015e64eae555cb24d625b0f36989.jpg

I chose AKG 95A bushing after asking Ray about his. He said no really noticeable Noise or vibration. All three bushings were torn. As you can see in the pics, you can't see the tears unless you flex the bushings. The rear bushing always tears on the side you cant see too. This is why I tell everyone that you have to take the diff out and flex to really check the bushings.

https://uploads.tapatalk-cdn.com/20180828/7219b530c3dc2871f004457d3622d777.jpg

https://uploads.tapatalk-cdn.com/20180828/1998bd861c8369c636ccfc336720b60a.jpg

https://uploads.tapatalk-cdn.com/20180828/a981dcaa364d79cf1123cb05e30c6983.jpg

https://uploads.tapatalk-cdn.com/20180828/468f18dd323718fec6406c1f8fce4499.jpg

https://uploads.tapatalk-cdn.com/20180828/de910791747beb26c57dbc4c68be2381.jpg

I used the Schwaban Bushing puller set to remove and replace. The set worked really well but I was disappointed that they didn't include a collar big enough to do the rear diff bushing. I had to use one from my master Ball joint set. Using an air gun to remove and install made the replacement a breeze. On any of these sets, make sure you lube the threads very well with grease. Not only will it make it easier to turn, the tool will last much longer. Another nice feature of the Schwaban set is they use a thrust bearing instead of a washer under the nut used for tightening. This makes the tool work much smoother and it will last much longer. As with the threads, keep the thrust bearing well lubricated as well.

I rebuilt the whole drive shaft using one of the kits from ECS tuning. It came with a Febi Guibo which is thicker and much stiffer tthan the OEM guibo. I was happy about that. Upon first inspection, the guibo I took out appeared to be in perfect shape but upon closer inspection I could see that there were surface cracks in the rubber and it was pretty flexible as well.
Separating the driveshaft wasn't difficult but it helped having a fine toothed ratcheting box end wrench. I used a chisel to get the old center bearing off.

https://uploads.tapatalk-cdn.com/20180828/591e0149a741cde3542b7a4fa3382690.jpg

https://uploads.tapatalk-cdn.com/20180828/7fe6846f0dd723617ba5a1c7d125a266.jpg


A lot of people choose not to replace the centering bearing in the front of the drive shaft but I rebuild everything while I have it out. I cut the threads off a 1/2' shanked bolt, tapered the end and used this to remove the bearing. Fill the hole with grease and use a hammer to drive the bearing out. Refill with more grease as the bearing starts to come out. When driving in the new bearing, Make sure you don't drive it in all the way. It's supposed to stick out a bit. Use the marks on the old bearing to tell how far to drive it in.
When I reinstalled the drive shaft, I couldn't get it back in. I'm guessing that the Poly diff bushings didn't give enough to pop ii in. I ended up having to loosen all the diff bolts and slide the diff back a bit to get the drive shaft in place.

https://uploads.tapatalk-cdn.com/20180828/8109e5be476dc9d17ce0c363475e3ef0.jpg

https://uploads.tapatalk-cdn.com/20180828/7af663d1324077a948f5fd506e8f10b0.jpg

https://uploads.tapatalk-cdn.com/20180828/2358edb47e149665fd0c894cebf591e1.jpg

I used ECS adjustable lower control arms so I could get my camber back into stock spec. My last set of tires went pretty quick. I chose these control arms because the adjusters are in the middle, making them much easir to adjust. In hindsite, i wish i had gotten steel control arms. Although the aluminum control arms are much lighter. I'm concerned about corrosion amd the nuts are aluminum which is easily galled and stripped. I used a ton of antiseize compound on the adjusters, threads and nuts.
I used the Schwaben puller set again on the lower control arm bushings. I replaced with OEM rubber. It literally took more time to get the tool setup than to get the bushing out/in with the air gun-sweet! The bolt for the left lower bushing was seized in so I had to get creative to get that side out. I used a drill bit to drill out to rubber and remove the center then used a chisel to get out the metal. Not too difficult but time consuming.
I guessed the camber settings, reassembled everything and took for alignment... apparently, my guess wasn't too far off after looking at the before/after on the alignment sheet :)

https://uploads.tapatalk-cdn.com/20180828/bb3aa7a204e4ee90d667c8a0e69f14d4.jpg

I showed the kids all the stuff under the car, they loved it!

https://uploads.tapatalk-cdn.com/20180828/30b60603019da24768a2ddd11b6af316.jpg

https://uploads.tapatalk-cdn.com/20180828/7ab0dfbd69c1073e8576cee2849b9d65.jpg

[az3579]

Interesting how Ray said he has no noise or vibration with the AKG 95A bushings. That is exactly what I just ripped out of my car because I couldn't stand the clunking they transmitted to the cabin. lol

I didn't mind the diff whine on decel, but the clunking had to go.

What are your thoughts now that it's in? Or are you not finished yet?

[Sockethead]

The bit of gear whine I had before (not sure where it's coming from) hasn't really gotten any louder and no clunking or anything. My clutch/flywheel is pretty noisy so it's hard to tell.
Ray did say that after 20K or so (IIRC) that they started getting louder but 20K will take me years to put on my car

[san]

The bit of gear whine I had before (not sure where it's coming from) hasn't really gotten any louder and no clunking or anything. My clutch/flywheel is pretty noisy so it's hard to tell.
Ray did say that after 20K or so (IIRC) that they started getting louder but 20K will take me years to put on my car

I got rid of the whine by changing the fluid in my diff...


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[johnrando]

Wow, lots of work, glad you got 'er done.

Sent from my SM-G955U using Tapatalk

[Sockethead]

Yea John, slow progress but any progress is good.

San, I have a Diffs online center section with polished gears. I don't think the whine is from that. I changed the diff oil before moving down here. It may be a wheel bearing. I'll just have to wait until it gets louder so I can ID it. I do get a little gearbox whine. It usually goes away when I change the fluid but that noise is easily identifiable because the it changes pitch with engine speed and gear changes...

[Sockethead]

I got to spend a little time working on the car between hurricanes and sick kids and started to mock up the new heat exchanger.
This thing is massive and it’s going to need to be modified to work the way I want it to
I had to cut out the aluminum bumper brace so it can sit into it.
Also turned it upside down so the inlet/outlet are on the same side as the pump. I’m going to cut the original bracket off since it’s now on the bottom in this configuration and I’ll have to design new mounting brackets. There are 4 unused studs on the radiator support that I’m hoping to utilize for that.

I wish I knew how to weld aluminum. It would make this much easier because I’m going to have to get someone to weld it all for me off the car. Ideally, I’d want to be able to tack weld every thing in place on the car then finish welding off the car

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[Johnmadd]

Nice Rob!

[johnrando]

+1

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[BADCLOWN]

When I go SC on mine, would installing an IC be one of those “might as well” mods to do when the charger is installed? I only plan on running 5-8psi off the top and maybe increasing later

That IC looks pretty thick, where did you get it at (I may have missed this)?

[Sockethead]

+1



Nice Rob!

Thanks guys... lots of time consuming fabrication but it will be very satisfying when it's done.



When I go SC on mine, would installing an IC be one of those “might as well” mods to do when the charger is installed? I only plan on running 5-8psi off the top and maybe increasing later

That IC looks pretty thick, where did you get it at (I may have missed this)?

I could of sworn I replied to this but I guess I didn't...
If they have a kit for an intercooler and it's within your budget, then yea, I'd do it at the same time. Cooling the mixture at any boost pressure won't hurt. These engines can take quite a bit of boost stock (up to 12 psi if tuned and cooled right) The limiting factor is an auto trans. You can't much above 6psi with an auto. I'd start with 8psi with a manual...

The heat exchanger I have is made by AFCO for a Ford Lighting. I think it's thicker than the enine's radiator lol

[johnrando]

Knew Rob would have the answer.

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[Sockethead]

Finally getting the mounts for the heat exchanger done. I just don’t have the resources to do it the way I want... with out making it look like some one did it in their garage with a vise and a hacksaw because that’s basically all I got and my Mig isn’t setup for aluminum.
My car is here at Nth degree fabrication. They do amazing work...

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They’re old school which I really like


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And that have Bimmers!

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