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  • My Turbo Rebuild

    So, after detonating my engine at Easter 2005 I have spent the last 15 or so months contemplating how to go about rebuilding the engine. You could say I took my time but I wanted to do it once and do it right…..once.

    Having spoken to many a guru and done as much research on various ongoing projects around the world, I have decided that the only option that really excited me was going FI.

    My stock 2.3 litre block is being inspected, decked and bored to 2.5 litres. It will also be O-ringed. I have got some very nice JE forged, high heat coated 95mm pistons from Steve at Top End Performance. The compression ratio is 8.1:1. Brand new OEM 2.5 litre crank from Don at McAdams Autosport. My mechanic also managed to track down some race prep’d rods (never used) from one of the old Benson & Hedges Race teams here in Australia. Top End Performance has also supplied ARP Main and Rod bolts, along with ARP Head Studs. Multi Layer Steel 1.8mm Head Gasket from Cometic Gaskets I will be running the EVO III oil pump.

    My head was sent out to the engineers and was cleaned up and then ported and polished. New heavy duty valve springs were put in along with the stock cams and the rest of the valve train. Stock cams are ideal for my application. I have kept the 46mm TB.s and plenum at this stage. I may have a custom plenum made a bit later on if it needs it. I will be running Delphi 780cc injectors and a new Bosch 044 ‘Motorsport’ Fuel Pump. I am getting a custom made, ceramic coated turbo manifold and dump pipe done up at the moment.

    The turbo is a new Garrett GT35R Turbocharger and I will be running around 1.2 to 1.3 bar boost. (18 – 20psi) Tail 44mm Wastegate and Turbosmart plumbed back dump valve. I also have a PWR Intercooler and Radiator.

    I have recently picked up a Motec ECU with the latest software upgrades and also some gauges form Defi in Japan.

    There is plenty of other stuff to throw in here but I will keep this thread updated as it progresses. I hope to have it back on the road by late October early November.

    Now, what will it be making when it’s finished I hear you ask? I would think somewhere around 430hp at 1.2bar boost would be a safe assumption. Only time will tell.

    My biggest problem is finding some good pics of the E30 M3 front bar cut nicely to fit an intercooler, as I dont want the big jap look. I will paint the intercooler black to remain more subtle.

    Cheers
    Dave


  • #2
    Love to hear it.

    What a/r is the turbo gonna be?
    You dont think a gt30r would be better suited for the s14?
    Are you top mounting the turbo?

    "Unlike the latter day E36 and E46 M3's, the
    original E30 M3’s main purpose in life was to
    win races on the track, not the street. It
    got the job done."

    Comment


    • #3
      Originally posted by CeeP
      What a/r is the turbo gonna be?

      .82
      Originally posted by CeeP You dont think a gt30r would be better suited for the s14?
      That was the original plan, but we think the GT35r will do the job with less fuss. They have a good reputation for spooling up nicely as well. As with all turbo applications, it may come down to some months of R&D
      Originally posted by CeeP Are you top mounting the turbo?
      No

      Comment


      • #4
        Remembered this one from a while back:





        http://www.cardomain.com/ride/657919/10
        -Eric

        Comment


        • #5
          That sounds truly awesome! No doubt it will be top notch
          "It is needless to say that self-propelling vehicles, like other machines, will never do as much for one who does not understand them as for one who does."

          Comment


          • #6
            gt35r is too big if ur running only 1.2 bar of boost


            what is this said evo iii oil pump? pn?

            Comment


            • #7
              No top mount?

              I thought I read in Turbo Todd's thread that there wasnt too much room down there for a turbo. Maybe I am wrong?

              "Unlike the latter day E36 and E46 M3's, the
              original E30 M3’s main purpose in life was to
              win races on the track, not the street. It
              got the job done."

              Comment


              • #8
                Originally posted by Mr Deagle
                gt35r is too big if ur running only 1.2 bar of boost
                I am happy for people to put a point of view over, but please, lets back it up with something.
                Originally posted by CeeP
                No top mount?

                I thought I read in Turbo Todd's thread that there wasnt too much room down there for a turbo. Maybe I am wrong?
                Plenty of room.
                Another S14.net members car.

                Last edited by OZM3; 07-19-2006, 07:39 PM.

                Comment


                • #9
                  Originally posted by OZM3
                  I am happy for people to put a point of view over, but please, lets back it up with something.
                  lets turn our attention to the turbo map here

                  as you can see there is a graph representing flow rate, turbine wheel speed, and boost pressure...you said that you were going to be running 1.2 to 1.3 bar of boost, that turbo has a maximum boost of 2.25 (around) and your boost range puts you at the bottom of the graph, which means that you could run a smaller turbo, have less lag and still have the performance that you want....

                  edit: go w/ the gt35r if you really want...you already have it
                  Last edited by Mr Deagle; 07-19-2006, 08:32 PM.

                  Comment


                  • #10
                    Good luck with it OZM3!! I assure you you will love it!!

                    How close do you think the GT35R will be to surging? I think its a good idea to get the biggest turbo you can to start with as you will keep winding the boost up!! By my calculations you can run upto (roughly) 1.38 BAR (20psi) with that compression ratio!!!! Thats GT35R!!!

                    I've got some JE pistons from Steve @ Topend as well now. And the cometic gasket and ARP head studs!! I've gone for 7.8:1 with a view to running just over 20PSI. I dream about GT series turbos as I'm not convinced mine will be "man" enough.

                    I'm leaving the 84mm crank in though which leaves it approx 2380cc. Purely a cost thing for me.

                    Its nice to see a pic of my M3 again, brings a tear to my eye though.

                    Make sure to keep us all up to date.........
                    I'm dropping the hammer!!!!!

                    Comment


                    • #11
                      Originally posted by Mr Deagle
                      lets turn our attention to the turbo map here

                      as you can see there is a graph representing flow rate, turbine wheel speed, and boost pressure...you said that you were going to be running 1.2 to 1.3 bar of boost, that turbo has a maximum boost of 2.25 (around) and your boost range puts you at the bottom of the graph, which means that you could run a smaller turbo, have less lag and still have the performance that you want....
                      Remembering that 1 bar boost is 14.7 psi, 1.3 bar is approxiametly 18.85psi or a pressure ratio of 2.3 on the map. 1 on the pressure ratio scale is zero psi. Now having calculated my Corrected Air Flow using a table designed by Jacob Fannon over at Bimmerforums you can plot the entire rev range of the motor. You can see the turbo is at its most efficiant at around 6700rpm and 41ish lb/min. I think it should be just perfect and should yield somewhere north of a very useable 420hp.

                      Did you read 1.3 bar boost as 1.3 bar pressure ratio on the GT35R map? Then your calculations would be right.

                      Originally posted by martybee58
                      Good luck with it OZM3!! I assure you you will love it!!

                      How close do you think the GT35R will be to surging? I think its a good idea to get the biggest turbo you can to start with as you will keep winding the boost up!! By my calculations you can run upto (roughly) 1.38 BAR (20psi) with that compression ratio!!!! Thats GT35R!!!

                      I've got some JE pistons from Steve @ Topend as well now. And the cometic gasket and ARP head studs!! I've gone for 7.8:1 with a view to running just over 20PSI. I dream about GT series turbos as I'm not convinced mine will be "man" enough.

                      I'm leaving the 84mm crank in though which leaves it approx 2380cc. Purely a cost thing for me.

                      Its nice to see a pic of my M3 again, brings a tear to my eye though.

                      Make sure to keep us all up to date.........
                      Marty. Thank you. It was your original post that broke the camels back so to speak. I was going to go a lower CR on my pistons but felt I would start here. 20psi is a long term aim after I have a better understanding. At under a $900USD shipped to me in Australia for a set of pistons from steve, I figure I can afford to throw in some lower ones in a couple of years and see how far it can be pushed.

                      Dave
                      Last edited by OZM3; 07-20-2006, 12:12 AM.

                      Comment


                      • #12
                        I was well impressed with the price and service from Topend as well

                        Have you decided on a clutch yet? I think I'll be going for one of these as soon as funds allow.....

                        http://cgi.ebay.com/ebaymotors/ws/eB...RK%3AMEWA%3AIT

                        What do you think?

                        I emailed and asked what the rated capacity was and was told 350BHP. But from my experience you'll be hard pushed to get any manufacturer to rate higher than that. After all, I was running a stock clutch with around 330BHP and it held ok (over 2000 hard miles) until I asked it to do a couple of 0-60 runs which it was nt too happy about. :sosad:
                        I'm dropping the hammer!!!!!

                        Comment


                        • #13
                          Originally posted by OZM3
                          I am happy for people to put a point of view over, but please, lets back it up with something.

                          Plenty of room.
                          Another S14.net members car.

                          exactly, thats a top mounted turbo though.
                          You said you werent running a top mount.

                          Great project though. I'm sure I'm gonna have a lot of questions for you and be sure to take a lot of pics!
                          Last edited by CeeP; 07-20-2006, 07:54 AM.

                          "Unlike the latter day E36 and E46 M3's, the
                          original E30 M3’s main purpose in life was to
                          win races on the track, not the street. It
                          got the job done."

                          Comment


                          • #14
                            Originally posted by martybee58
                            Have you decided on a clutch yet? I think I'll be going for one of these as soon as funds allow.....
                            I have a contact with the people that own Sachs clutches so I will see what they have to offer. That looks like it will do the trick. Any major clutch specialist in the UK should be able to put together a decent HD clucth for you though.
                            Originally posted by CeeP
                            exactly, thats a top mounted turbo though.
                            You said you werent running a top mount.

                            Great project though. I'm sure I'm gonna have a lot of questions for you and be sure to take a lot of pics!
                            Ah ok, I have a different understanding of a top mount turbo. I am removing my water washer bottle and relocating a smaller one on the other side of the engine bay. I am still undecided about removing the AC or not.

                            Comment


                            • #15
                              Nice project Dave!
                              Todd Crossley used a volvo intercooler that is shaped same as the radiator and mounts in front of the radiator. Totally inconspicous if it would be proper size for what you need.
                              Good luck with this, sounds like you are off to a good start.
                              John
                              88M3 henna


                              73T100C
                              97 540\6-Gone
                              2008 MINI Clubman S

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