[OpenFlash]

Captain Insano's 2007 e90 6MT is going to break some hearts. As well as all of our old, yet still standing, 1/4 mile and 60-130mph world records!



Details:
2007 335i 6MT
Lots of miles (over 70k)
Lots of track time at Laguna
Lots of oil coolers
Some ridiculous clutch with LWFW
VFF in-line fuel pump
Upgraded fuel rail
Bilstein Coilovers
Flared fenders with wide wheels wrapped in Toyo R888s
VFF900 (6466 Twin Scroll)
Vishnu PWM Meth
Procede+OpenFlash Tablet

Since the last time we tested the car, it make a healthy 700whp at 26psi.

Since then, it has been converted over to a disturbingly beautiful twin scroll manifold. Looks about the same from up top, but when viewed on the engine stand, it's a work of art. It's so well fabricated I want to punch myself in the face whenever I look at it:



The turbo has been upgraded to a larger 1.0 hotside with divided housing (twin scroll). This means dual wastegates and a lot more work for the fabricators (see above).

Today we finally got some time to visit a Dynojet at DNR Performance, Hayward CA. FFTEC's in-house Dyno is a Mustang Dyno and, while great for initial calibration/tuning, its not the best for dyno comparisons since it's so configurable.. as it should be for tuning!). Our goal was to run 27-28psi and see what this magic turbo can do.

First several runs of the day were at 24-25psi:

Datalog:

Another datalog:


No matter how much we raised boost target up top, we couldn't make any more peak power. Power just stopped climbing at 6700rpm, limiting power to a disappointing 707whp.

The datalogs revealed that we weren't hitting our boost targets above 6700rpm. No matter how much WGDC we added, nothing helped. Turns out we the 10psi WG springs weren't stiff enough to be controlled over 25psi using the dual port wastegate control solenoid set-up we decided to use. The dual port set-up offers incredibly good accuracy and resistance to overshoot. But with all electronic wastegate control setups, you need to choose your mechanical WG spring just right (not to stiff, not too soft) and this is often a trial and error thing. So you say this is one of those errors.

Refusing to go back to the shop, install stiffer WG springs and come back next week, we decided to get a little creative. So we changed the wastegates boost reference signal from the nipple on the turbo's compressor housing to a nipple on the intake manifold. What this essentially does is compensate for a little pressure loss cause induced by the FMIC. Which should mean just a tad bit more boost up top. Not the 28psi (775+whp) we were targeting. But just maybe 25.5. It worked. Just barely! 738whp. Not close to we were aiming for when we first came to dyno tonight. But at least good enough to break the existing world record by a good margin. And more importantly, with broader, much more useful powerband. Did I mention this thing holds power until the rev limit @ 7300?



Datalog:


And sometime during this dyno session, I inadvertantly did a run in Map1 (low boost (22psi) with no meth:


Next:
Stiffer wastegates are going in next. Then back to the dyno to run at full boost. And then 60-130 acceleration tests (high 5s or go home!). And then to the dragstrip to break my own N54 WR time of 10.8@132 from last year. Compared to my car, this car is making about 100whp more with way more top end power. It should run low 10s

Big props to Captain Insano for being insane enough to let us build and tune something like this for him to drive on the street and race on weekends.

Best Regards,
Shiv

PS. Video to come next week. The car sounds rad. Way different than our previous single scroll single turbo cars.

[FrozenM3nace]

Vishnu I'm confused is the twin scroll on the N55 motor? So is this 739WHP on a N55?

[3000GT MR]

Originally Posted by Hyare1

Vishnu I'm confused is the twin scroll on the N55 motor? So is this 739WHP on a N55?

It's the vishnu/fftec twin scroll for the n54

[V8bait]

It's a custom twinscroll on a n54 engine. Stock longblock afaik. Impressive numbers for sure, what turbo is this again?

Twin scroll or twin fans is where it's at imo.

[3000GT MR]

Awesome numbers! A little confused about the limiting factor as stated on FB. I would like to see the captains single vs twin scroll overlay perhaps boost too.

[OpenFlash]

Originally Posted by 3000GT MR

Awesome numbers! A little confused about the limiting factor as stated on FB. I would like to see the captains single vs twin scroll overlay perhaps boost too.

We are using twin external wastegates with 10psi springs. They are too soft to suppose any more than 25psi in the dual port wastegate configuration we run. Kind of a bummer because we were hoping to tune it up to 27-28psi tonight and shoot for 765-775whp.

The twin scroll 6466 runs a big 1.0 hot side and makes full boost at 4500rpm. Peak HP at rev limit (7300rpm) with no signs of slowing down above that. Amazing power with a ridiculously wide powerband. More later

[3000GT MR]

Originally Posted by shiv@vishnu

We are using twin external wastegates with 10psi springs. They are too soft to suppose any more than 25psi in the dual port wastegate configuration we run. Kind of a bummer because we were hoping to tune it up to 27-28psi tonight and shoot for 765-775whp.

The twin scroll 6466 runs a big 1.0 hot side and makes full boost at 4500rpm. Peak HP at rev limit (7300rpm) with no signs of slowing down above that. Amazing power with a ridiculously wide powerband. More later

That's some serious exhaust pressure. Why don't you just hook up the top ports on the wastegates?

[3000GT MR]

Disregard i just reread what you said

[Ilma]

Originally Posted by shiv@vishnu

Captain Insano's 2007 e90 6MT is going to break some hearts (and some of our old acceleration records I'm sure).

Pics, video and dyno graphs to come in the morning. But here is the gist of it.

Race gas alone: 665whp @ 22.5psi
Race gas with meth: 739whp @ 25psi

Tune: Procede+OpenFlash Tablet

So is that stacked then?

.

[OpenFlash]

Originally Posted by Ilma

So is that stacked then?

.

Yes Procede with a tweaked version of our OTS ProcedeFlash (single turbo) back end flash. Tweaked to allow full power up to 7300rpm. This was our comfort limit, not necessarily the engine's. And yes, it's 100% stock. And heavily roadraced.

[klipseracer]

Impressive numbers. I'd love to see it at 27-30psi

[CaptainInsano]

Road raced, over-revved, neglected, and still kicking

This is sick. I need more oil coolers.

[OpenFlash]

Originally Posted by CaptainInsano

Road raced, over-revved, neglected, and still kicking

This is sick. I need more oil coolers.

NO please no more coolers! As it is, with your enormous coolers, it takes forever to warm the car up on the dyno. And by the time it's warm, the room is so contaminated with exhaust it defeats the purpose of cool, non-heatsoaked run.

Shiv

[CaptainInsano]

Originally Posted by shiv@vishnu

NO please no more coolers! As it is, with your enormous coolers, it takes forever to warm the car up on the dyno. And by the time it's warm, the room is so contaminated with exhaust it defeats the purpose of cool, non-heatsoaked run.

Shiv

I'll get it to overheat. Trust me.

[YMB_M3]

not impressive for this turbo
on race gas alone it should be making appox 750whp
something is limiting this turbo whether it be the manifold or tuning or both lol
whats the deal with only 22.5 psi on race gas you should be able to crank up the boost but can't tell without any logs. post some logs
for a high compression motor with a 6466 this is kind of embarassing lol

[135iDCT]

rwhp on pump gas only?

[Stage 2 Drew]

I'm guessing its out of injector, hence why the meth makes so much more power with only 2.5psi more.

[OpenFlash]

Pictures, datalogs and dyno graphs just added to first post

[OpenFlash]

Originally Posted by 135iDCT

rwhp on pump gas only?

Been there, done that. Made over 600whp on 91oct with the single scroll 6466. The purpose of this tuning session was to make big power.

[OpenFlash]

Originally Posted by Stage 2 Drew

I'm guessing its out of injector, hence why the meth makes so much more power with only 2.5psi more.

When meth isn't spraying, the Procede runs a more much more conservative ignition advance curve. Also, without meth spraying IATs are higher which means air density is lower. Both cause power losses far greater than the 2.5psi lower boost pressure would suggest.

[OpenFlash]

Originally Posted by kkashanchi

not impressive for this turbo
on race gas alone it should be making appox 750whp
something is limiting this turbo whether it be the manifold or tuning or both lol
whats the deal with only 22.5 psi on race gas you should be able to crank up the boost but can't tell without any logs. post some logs
for a high compression motor with a 6466 this is kind of embarassing lol

Try reading the fist post

[135iDCT]

Originally Posted by shiv@vishnu

Been there, done that. Made over 600whp on 91oct with the single scroll 6466. The purpose of this tuning session was to make big power.

How much gains do u think for the twin scroll at same boost?
can u tell us the difference between the 6466 single and twin scroll