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BMW 3-Series (E90 E92) Forum > E90 / E92 / E93 3-series Powertrain and Drivetrain Discussions > N57 / M57 Turbo Diesel Discussions - 335d > Seriously, block your EGR (pictures inside)



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      04-01-2014, 12:44 PM   #45
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Let me also apologize for the largest pictures ever seen on a forum.......
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      04-01-2014, 12:51 PM   #46
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Wow...great work Iaknown. That looks like an impressive piece. Really like the recessed design for the flared edge to recede into so as to minimize forward spacing. I'm by no means a metallurgist, but what temps do you expect this piece will see as it is right there off the manifold and near the turbos? Assume this piece is robust enough to deal with the temps?

Great work!!!!
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      04-01-2014, 12:52 PM   #47
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God damn thats some sweet thing there amigos let me know when you start production, my friend is in 1st stage of making the DPF, he removed his DPF and starting to make the flanges and eventually the pipe
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      04-01-2014, 01:14 PM   #48
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Quote:
Originally Posted by Mark M View Post
Wow...great work Iaknown. That looks like an impressive piece. Really like the recessed design for the flared edge to recede into so as to minimize forward spacing. I'm by no means a metallurgist, but what temps do you expect this piece will see as it is right there off the manifold and near the turbos? Assume this piece is robust enough to deal with the temps?

Great work!!!!
Good question. And I think we discussed this on another thread. My reasoning is that the EGR pipe is also stainless steel and only .040" thick. This block-off is twice that at its thinnest point (where the flare meets the center body). Plus there is a big whopping center that will see most of the heat. So something else would have to give before this does. Not to mention once you block this path off there is no flow there. So it's no longer in the exhaust stream.....Basically what I'm getting at is the EGR is blocked when not in use and only contained by a .040" walled pipe and there are no issues. So there is a pretty big safety margin here if you think about it......
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      04-01-2014, 04:36 PM   #49
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Iaknown, are you able to provide a SolidWorks file or just .pdf output of such to someone interested making their own. Of course at a promise that it shall not be commercialized. Just saves taking things apart for measurement.
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      04-01-2014, 07:05 PM   #50
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Quote:
Originally Posted by Mark M View Post
Wow...great work Iaknown. That looks like an impressive piece. Really like the recessed design for the flared edge to recede into so as to minimize forward spacing. I'm by no means a metallurgist, but what temps do you expect this piece will see as it is right there off the manifold and near the turbos? Assume this piece is robust enough to deal with the temps?

Great work!!!!
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      04-01-2014, 07:14 PM   #51
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By the way, we are using a similar but thinner plate on the EGR block offs for our Powerstrokes....which make 600+hp and over 1100 ft lb of torque. The metal will hold up just fine :-)
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      04-01-2014, 07:16 PM   #52
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Quote:
Originally Posted by Yozh View Post
Iaknown, are you able to provide a SolidWorks file or just .pdf output of such to someone interested making their own. Of course at a promise that it shall not be commercialized. Just saves taking things apart for measurement.
Well first I'd like to confirm fit with someone. When are you planning on installing?

I also told Hooper I'd get him one, you still interested Hooper?
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      04-01-2014, 10:53 PM   #53
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Yeah I'm definitely still interested. I'm starting on another unrelated project right now that's going to take up all my tinkering time for a while so if you are looking to get feedback on it you should probably send one off to someone else.
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      04-02-2014, 01:32 PM   #54
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very excited to see this taking shape! once we start to see some more established results, this will most likely be the first "modification" to mine once the factory warranty lapses. keep up the good work!
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      04-02-2014, 02:43 PM   #55
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Quote:
Originally Posted by iaknown View Post
Well first I'd like to confirm fit with someone. When are you planning on installing?

I also told Hooper I'd get him one, you still interested Hooper?
Thanks Iaknown, I will install mine as soon as I map a template for the block off plate on the EGR side. Will do it this weekend, then Solidworks and then manufacture. Then I can install both, EGR side and Cooler Inlet side. Like your design very much. Can wait for fitment testing though.
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      04-02-2014, 02:58 PM   #56
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Quote:
Originally Posted by Yozh View Post
Thanks Iaknown, I will install mine as soon as I map a template for the block off plate on the EGR side. Will do it this weekend, then Solidworks and then manufacture. Then I can install both, EGR side and Cooler Inlet side. Like your design very much. Can wait for fitment testing though.
Where are you located? How about I send you one to try along with a disc to block off the other end with the condition that you can install and let me know how it fits?
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      04-02-2014, 03:08 PM   #57
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I would be happy to participate in test fitting if you can spare one. By then I shall have the other block off plate made and will fit them together. Pictures, measurements, evaluation is to be provided of course. I'm in Vancouver, Canada (West Coast, 2 hrs from Seattle), but have a US shipping address so it is cheaper to ship and can pay for shipping of course. Let me know and I shall PM my address to you.
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      04-02-2014, 04:05 PM   #58
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How much is a egr block in the uk
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      04-02-2014, 05:00 PM   #59
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Quote:
Originally Posted by Yozh View Post
I would be happy to participate in test fitting if you can spare one. By then I shall have the other block off plate made and will fit them together. Pictures, measurements, evaluation is to be provided of course. I'm in Vancouver, Canada (West Coast, 2 hrs from Seattle), but have a US shipping address so it is cheaper to ship and can pay for shipping of course. Let me know and I shall PM my address to you.
Do not worry about the EGR block-off, I will send you a thin disc to block off there as well. Feel free to PM me and I will get these pieces on the way. The faster the better so we'll know if everything works.
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      04-02-2014, 05:00 PM   #60
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Quote:
Originally Posted by iaknown View Post
By the way, we are using a similar but thinner plate on the EGR block offs for our Powerstrokes....which make 600+hp and over 1100 ft lb of torque. The metal will hold up just fine :-)
Nice work!
Would it be possible for you to make one with a small opening in the middle of the cap, basically just reduce the stock EGR flow by ~60%. Maybe this way the OBD system will not trip, there will be some EGR helping with warming up the car, but reduced enough to maybe prolong/prevent excessive build up?

I'd be willing to try it out. Thanks
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      04-02-2014, 05:03 PM   #61
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Originally Posted by 135i_vs_ View Post
Nice work!
Would it be possible for you to make one with a small opening in the middle of the cap, basically just reduce the stock EGR flow by ~60%. Maybe this way the OBD system will not trip, there will be some EGR helping with warming up the car, but reduced enough to maybe prolong/prevent excessive build up?

I'd be willing to try it out. Thanks
Hmmm, interesting idea. What size hole? How soon do you plan to install as well?
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      04-02-2014, 06:12 PM   #62
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Regarding the hole size, measure the diameter at the outlet, size the new hole to be 40% of that diameter.

I can try it as soon as in 2 weeks.
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      04-02-2014, 06:50 PM   #63
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Nice piece
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      04-02-2014, 09:32 PM   #64
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Originally Posted by 135i_vs_ View Post
Regarding the hole size, measure the diameter at the outlet, size the new hole to be 40% of that diameter.

I can try it as soon as in 2 weeks.
You say outlet, I assume you mean outlet at the exhaust manifold or inlet of the actual cooler. That would make the most sense because I believe the outlet of the cooler (near the EGR valve) is larger than this?? You tell me. And PM me your address as well.
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      04-02-2014, 11:57 PM   #65
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Quote:
Originally Posted by iaknown View Post
Do not worry about the EGR block-off, I will send you a thin disc to block off there as well. Feel free to PM me and I will get these pieces on the way. The faster the better so we'll know if everything works.
PM Sent
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      04-03-2014, 03:10 AM   #66
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Quote:
Originally Posted by iaknown View Post
You say outlet, I assume you mean outlet at the exhaust manifold or inlet of the actual cooler. That would make the most sense because I believe the outlet of the cooler (near the EGR valve) is larger than this?? You tell me. And PM me your address as well.
Yes, outlet at the exhaust manifold.
Regarding sizing, I gave you the wrong formula, lol. To reduce the cross sectional area by 60%, it should be based off [0.6•(Pie•r^2)]. Or if you tell me the outlet diameter I can calculate it for you.

PM sent. Thanks,
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