Designing a lower cost, higher performance oil cooler solution

ashmostro · 05-07-2013, 09:22 AM

Update: With the help of Bimmer305 up above I was able to get some test-fit brackets machined and did a fitment check this weekend and ran into a small hitch that will require a v 2.0 of the brackets to be made- this time out of SS instead of Al in order to support a deep bend. It's definitely doable though so I'm looking forward to getting it all mounted up and then will take the brackets back down and tweak and trim before I'm comfortable with publishing the specs. The first versions will be very rough in appearance (though perfectly capable and strong).

More to come...

._. · 05-07-2013, 10:22 AM

Quote:

Originally Posted by ashmostro

Update: With the help of Bimmer305 up above I was able to get some test-fit brackets machined and did a fitment check this weekend and ran into a small hitch that will require a v 2.0 of the brackets to be made- this time out of SS instead of Al in order to support a deep bend. It's definitely doable though so I'm looking forward to getting it all mounted up and then will take the brackets back down and tweak and trim before I'm comfortable with publishing the specs. The first versions will be very rough in appearance (though perfectly capable and strong).

More to come...

Awesome! Thanks for the update.

srSheepdog · 05-08-2013, 12:11 AM

Quote:

Originally Posted by R 4 5 T 4 M 4 N

Awesome! Thanks for the update.

^^ this ^^

2010MSPORT335i · 05-08-2013, 04:29 PM

Interested

._. · 05-24-2013, 02:32 PM

any updates?

ashmostro · 05-24-2013, 06:52 PM

Yessirs.

First off, apologies for the slowness but I have good reasons for it. Firstly, I've been traveling for work due to an org change and have been at home on average one day a week for the past month and a half. Two, I'm getting married on June 1 and we've been pretty swamped with all of that.

That said, I'm going to mock up brackets v. 2 tomorrow and send it over for fabbing so hopefully will have something to test after I get back from our honeymoon. I really wanted to get to it before the wedding but it just wasn't feasible given how I've pretty much not been home and when I have been, I kind of had to focus on the wedding.

Sorry for the inconvenience folks, but the prototype will get done in the next few weeks.

ashmostro · 05-25-2013, 04:43 PM

Updated design sent to fabrication! This should be a more successful design.

I'm planning to use some perforated SS sheet for the fender well vent, riveted to the fender plastic from the inside. Can get it off amazon for a good price.

dsjr2006 · 05-25-2013, 05:34 PM

Pretty excited for this!

psmitty95 · 05-25-2013, 06:49 PM

Awesome, keep us updated. The one you're focusing on right now is the retrofit not just upgrade, right?

ashmostro · 05-25-2013, 07:07 PM

Correct

Vigorous · 05-25-2013, 07:50 PM

Retrofit oil cooler? YES PLEASE!
Thanks for the efforts!

ashmostro · 05-25-2013, 08:28 PM

Wait i need to make sure were on the same page here... I'm making a kit that replaces an existing factory cooler with a larger, more efficient one. if you have an e9x without a cooler you might be able to add this with the necessary factory parts but i will do that research after i develop this first.

Vigorous · 05-25-2013, 09:13 PM

^^ still definitely helpful

ken1137 · 05-25-2013, 10:00 PM

subscribed.

ashmostro · 07-07-2013, 07:48 PM

The day has come! Sort of. The (semi) final version of the bracket was sent to me a week and a half ago and I was able to mount everything up today and do a shakedown run. The reason I said "semi-final" is because with everything hooked up I see that a slight angle could be built into the bracket to improve clearances in the wheel well. As such, I will be modifying the bracket drawing slightly to see if a v3 can be made to make the wheel well installation much cleaner, and to use the perforated steel sheet I bought to use as a protective cover for the backside of the cooler - right now it's fully exposed which I'm comfortable with for a while on the street, but not on the track.

Here are some pics of the install, but keep in mind the cooler angle will change slightly - the bottom edge will tilt more towards the front of the car.

As for performance, since I only did a shakedown run to my bday dinner tonight after the install (my wife was not entirely pleased), all I can say is the oil temp did take longer to come up than I am used to - I have been running a thermostat delete. Tomorrow's commute will give me more normalized data and I will report back.

Stay tuned for another post detailing all of the parts I bought and where to get them all from, as well as the CAD drawing for the bracket that is needed for this install. Turns out you only need one!

._. · 07-07-2013, 07:59 PM

awesome, thanks for the update.

Stock-ish · 07-13-2013, 12:53 PM

ashmostro: Excellent project and info. If you have a couple clear shots of how the bracket connects to the car, that would be greatly appreciated. Nice work.

Also, congrats on the wedding and the mod-friendly wife!

ashmostro · 07-13-2013, 02:21 PM

Happily Stock-ish - I don't want to put up too many pics of the current bracket because I don't like the clearance between the cooler and the tire currently. I'm taking some measurements this weekend to redesign it and hopefully I will be happy enough with the result to make it public.

I will not only post up pics, but a detailed CAD drawing of the bracket so anyone can reproduce it. Along of course with a complete parts list. I've got too many projects and work commitments going on or I would have gotten this done much sooner.

FWIW, I'm consistently getting readings 20-25 degrees below my previous setup (stock cooler, no thermostat) in daily driving. It looks quite promising for the track.

PS, thanks for the congrats - I know I'm a lucky guy- she let's me play with my toys and even buys me some

Stock-ish · 07-13-2013, 09:22 PM

Thanks! Looking forward to the details. I'm planning to start the search for a cooler-friendly filter housing then I'll be putting together my own setup in the stock location similar to yours. Any detailed information I can get prior to tearing apart my daily driver is helpful, so this thread is a gold mine in terms of research. Many thanks sir!

ashmostro · 07-13-2013, 09:25 PM

When you say "filter housing" do you mean the adapter fittings for the AN lines coming out of the stock thermostat?

If so, this is what I used: http://www.turnermotorsport.com/p-42...6-e82-e9x.aspx

Stock-ish · 07-14-2013, 08:03 AM

I wish that was the case. My car came without an oil cooler at all, so I need to find the oil filter housing that has the thermostat and connections for the oil cooler lines to replace mine which has none of that.

I appreciate the link though. That'll probably be part of the setup once I find the filter housing.

ashmostro · 07-14-2013, 11:45 AM

Ah, understood. Sorry I misunderstood

If you haven't already started your list, check this post out: http://www.e90post.com/forums/showpo...25&postcount=4

05-07-2013, 09:22 AM	#89
ashmostro Brigadier General 1253 Rep 4,087 Posts Drives: 2020 M4cs \| 2022 M550i Join Date: Jan 2013 Location: Falls Church, VA iTrader: (27)	Update: With the help of Bimmer305 up above I was able to get some test-fit brackets machined and did a fitment check this weekend and ran into a small hitch that will require a v 2.0 of the brackets to be made- this time out of SS instead of Al in order to support a deep bend. It's definitely doable though so I'm looking forward to getting it all mounted up and then will take the brackets back down and tweak and trim before I'm comfortable with publishing the specs. The first versions will be very rough in appearance (though perfectly capable and strong). More to come...
	Appreciate 0 Quote

05-08-2013, 04:29 PM	#92
2010MSPORT335i Captain 95 Rep 951 Posts Drives: . Join Date: Sep 2009 Location: . iTrader: (7) Garage List 2010 E92 335i 6MT [0.00]	Interested
	Appreciate 0 Quote

05-24-2013, 02:32 PM	#93
._. Colonel 74 Rep 2,353 Posts Drives: BMW Join Date: Jun 2009 Location: Miami iTrader: (15)	any updates?
	Appreciate 0 Quote

05-24-2013, 06:52 PM	#94
ashmostro Brigadier General 1253 Rep 4,087 Posts Drives: 2020 M4cs \| 2022 M550i Join Date: Jan 2013 Location: Falls Church, VA iTrader: (27)	Yessirs. First off, apologies for the slowness but I have good reasons for it. Firstly, I've been traveling for work due to an org change and have been at home on average one day a week for the past month and a half. Two, I'm getting married on June 1 and we've been pretty swamped with all of that. That said, I'm going to mock up brackets v. 2 tomorrow and send it over for fabbing so hopefully will have something to test after I get back from our honeymoon. I really wanted to get to it before the wedding but it just wasn't feasible given how I've pretty much not been home and when I have been, I kind of had to focus on the wedding. Sorry for the inconvenience folks, but the prototype will get done in the next few weeks.
	Appreciate 0 Quote

05-25-2013, 04:43 PM	#95
ashmostro Brigadier General 1253 Rep 4,087 Posts Drives: 2020 M4cs \| 2022 M550i Join Date: Jan 2013 Location: Falls Church, VA iTrader: (27)	Updated design sent to fabrication! This should be a more successful design. I'm planning to use some perforated SS sheet for the fender well vent, riveted to the fender plastic from the inside. Can get it off amazon for a good price.
	Appreciate 0 Quote

05-25-2013, 05:34 PM	#96
dsjr2006 Captain 157 Rep 848 Posts Drives: '01 E39 540iA, '09 E90 M3 Join Date: May 2013 Location: Metro Detroit iTrader: (1) Garage List 2010 BMW 335i [0.00] 2001 BMW 540i [0.00]	Pretty excited for this!
	Appreciate 0 Quote

05-25-2013, 06:49 PM	#97
psmitty95 Brigadier General 578 Rep 4,393 Posts Drives: '23 M340i xDrive Join Date: Jan 2012 Location: Boston, MA iTrader: (11)	Awesome, keep us updated. The one you're focusing on right now is the retrofit not just upgrade, right? __________________ < Click picture for photoshoot E90 335i xDrive 6spd, Nav, Prem, Cold Weather, & Sports package - Msport Conversion Mods: JB4 + MHD, Doc Race ST, Pure 6266, AD-Eng PI/Mounts, Fuel-It st. 3, Custom Exhaust, Tuned by TwistedTuning More Pictures: Build Thread /// 683AWHP/675AWTQ
	Appreciate 0 Quote

05-25-2013, 07:07 PM	#98
ashmostro Brigadier General 1253 Rep 4,087 Posts Drives: 2020 M4cs \| 2022 M550i Join Date: Jan 2013 Location: Falls Church, VA iTrader: (27)	Correct
	Appreciate 0 Quote

05-25-2013, 07:50 PM	#99
Vigorous First Lieutenant 13 Rep 364 Posts Drives: BMW Join Date: Feb 2010 Location: Texas iTrader: (3)	Retrofit oil cooler? YES PLEASE! Thanks for the efforts! __________________ 2007 Montego Blue 335i Coupe / VRSF Downpipes / ETS Intercooler / Injen Intake / Alufelgen SF-71 Hyperblack / Orion V4 Angel Eyes / Aero Lip / M3 Side Skirts / CSL Trunk / Roof Spoiler / HID 3000k Fogs / Painted Shadowline Trim / Lowering Perches
	Appreciate 0 Quote

05-25-2013, 08:28 PM	#100
ashmostro Brigadier General 1253 Rep 4,087 Posts Drives: 2020 M4cs \| 2022 M550i Join Date: Jan 2013 Location: Falls Church, VA iTrader: (27)	Wait i need to make sure were on the same page here... I'm making a kit that replaces an existing factory cooler with a larger, more efficient one. if you have an e9x without a cooler you might be able to add this with the necessary factory parts but i will do that research after i develop this first.
	Appreciate 0 Quote

05-25-2013, 09:13 PM	#101
Vigorous First Lieutenant 13 Rep 364 Posts Drives: BMW Join Date: Feb 2010 Location: Texas iTrader: (3)	^^ still definitely helpful __________________ 2007 Montego Blue 335i Coupe / VRSF Downpipes / ETS Intercooler / Injen Intake / Alufelgen SF-71 Hyperblack / Orion V4 Angel Eyes / Aero Lip / M3 Side Skirts / CSL Trunk / Roof Spoiler / HID 3000k Fogs / Painted Shadowline Trim / Lowering Perches
	Appreciate 0 Quote

05-25-2013, 10:00 PM	#102
ken1137 Brigadier General 89 Rep 3,732 Posts Drives: BMW S1000XR Join Date: Jun 2011 Location: Gilbert, AZ iTrader: (7) Garage List 2009 e90 335i [6.40]	subscribed. __________________ BMWCCA member
	Appreciate 0 Quote

07-07-2013, 07:48 PM	#103
ashmostro Brigadier General 1253 Rep 4,087 Posts Drives: 2020 M4cs \| 2022 M550i Join Date: Jan 2013 Location: Falls Church, VA iTrader: (27)	The day has come! Sort of. The (semi) final version of the bracket was sent to me a week and a half ago and I was able to mount everything up today and do a shakedown run. The reason I said "semi-final" is because with everything hooked up I see that a slight angle could be built into the bracket to improve clearances in the wheel well. As such, I will be modifying the bracket drawing slightly to see if a v3 can be made to make the wheel well installation much cleaner, and to use the perforated steel sheet I bought to use as a protective cover for the backside of the cooler - right now it's fully exposed which I'm comfortable with for a while on the street, but not on the track. Here are some pics of the install, but keep in mind the cooler angle will change slightly - the bottom edge will tilt more towards the front of the car. As for performance, since I only did a shakedown run to my bday dinner tonight after the install (my wife was not entirely pleased), all I can say is the oil temp did take longer to come up than I am used to - I have been running a thermostat delete. Tomorrow's commute will give me more normalized data and I will report back. Stay tuned for another post detailing all of the parts I bought and where to get them all from, as well as the CAD drawing for the bracket that is needed for this install. Turns out you only need one! Last edited by ashmostro; 07-07-2013 at 08:01 PM..
	Appreciate 0 Quote

07-07-2013, 07:59 PM	#104
._. Colonel 74 Rep 2,353 Posts Drives: BMW Join Date: Jun 2009 Location: Miami iTrader: (15)	awesome, thanks for the update. __________________ 335i GONE --> V
	Appreciate 0 Quote

07-13-2013, 12:53 PM	#105
Stock-ish Accelerating one wheel at a time. 5 Rep 107 Posts Drives: Black 335i Sedan Join Date: Apr 2010 Location: Cleveland, OH iTrader: (0)	ashmostro: Excellent project and info. If you have a couple clear shots of how the bracket connects to the car, that would be greatly appreciated. Nice work. Also, congrats on the wedding and the mod-friendly wife!
	Appreciate 0 Quote

07-13-2013, 02:21 PM	#106
ashmostro Brigadier General 1253 Rep 4,087 Posts Drives: 2020 M4cs \| 2022 M550i Join Date: Jan 2013 Location: Falls Church, VA iTrader: (27)	Happily Stock-ish - I don't want to put up too many pics of the current bracket because I don't like the clearance between the cooler and the tire currently. I'm taking some measurements this weekend to redesign it and hopefully I will be happy enough with the result to make it public. I will not only post up pics, but a detailed CAD drawing of the bracket so anyone can reproduce it. Along of course with a complete parts list. I've got too many projects and work commitments going on or I would have gotten this done much sooner. FWIW, I'm consistently getting readings 20-25 degrees below my previous setup (stock cooler, no thermostat) in daily driving. It looks quite promising for the track. PS, thanks for the congrats - I know I'm a lucky guy- she let's me play with my toys and even buys me some Last edited by ashmostro; 07-13-2013 at 02:45 PM..
	Appreciate 0 Quote

07-13-2013, 09:22 PM	#107
Stock-ish Accelerating one wheel at a time. 5 Rep 107 Posts Drives: Black 335i Sedan Join Date: Apr 2010 Location: Cleveland, OH iTrader: (0)	Thanks! Looking forward to the details. I'm planning to start the search for a cooler-friendly filter housing then I'll be putting together my own setup in the stock location similar to yours. Any detailed information I can get prior to tearing apart my daily driver is helpful, so this thread is a gold mine in terms of research. Many thanks sir!
	Appreciate 0 Quote

07-13-2013, 09:25 PM	#108
ashmostro Brigadier General 1253 Rep 4,087 Posts Drives: 2020 M4cs \| 2022 M550i Join Date: Jan 2013 Location: Falls Church, VA iTrader: (27)	When you say "filter housing" do you mean the adapter fittings for the AN lines coming out of the stock thermostat? If so, this is what I used: http://www.turnermotorsport.com/p-42...6-e82-e9x.aspx
	Appreciate 0 Quote

07-14-2013, 08:03 AM	#109
Stock-ish Accelerating one wheel at a time. 5 Rep 107 Posts Drives: Black 335i Sedan Join Date: Apr 2010 Location: Cleveland, OH iTrader: (0)	I wish that was the case. My car came without an oil cooler at all, so I need to find the oil filter housing that has the thermostat and connections for the oil cooler lines to replace mine which has none of that. I appreciate the link though. That'll probably be part of the setup once I find the filter housing.
	Appreciate 0 Quote

07-14-2013, 11:45 AM	#110
ashmostro Brigadier General 1253 Rep 4,087 Posts Drives: 2020 M4cs \| 2022 M550i Join Date: Jan 2013 Location: Falls Church, VA iTrader: (27)	Ah, understood. Sorry I misunderstood If you haven't already started your list, check this post out: http://www.e90post.com/forums/showpo...25&postcount=4
	Appreciate 0 Quote