EPIC BUILD!!! - Top Mount PT6262 M Coupe Turbo - BMW 3-Series (E90 E92) Forum

94JZA80 · 09-11-2009, 09:40 PM

as the title suggests, my brother Brian has been performing surgery on his 1999 Z3 M Coupe for the past month or so with the help of our good friend and fabricator Shawn of Fifteen52 (1552v2.com). i originally wanted to start this thread back when Brian first started the project, but i just didn't have the time until now. at this point, the build part of the project is essentially done and is just awaiting a tune. however i will do my best to "cut and paste" the pictures and updates from another forum so that you can all see the progress and ask questions. i'm sure some of you are members on one or more of the boards we posted a build thread on (such as bimmerforums.com), and may already be familiar with this particular build. nevertheless, i thought this would be a good place to post it as well, since you 135i and 335i guys are boost junkies too

. currently i don't believe either Brian or Shawn are members here, but i will get them to create accounts so they can converse and field questions as well. so without further ado, on to the build...

Parts List:
Precision PT6262, Billet Wheel, 4” Inlet, 3” V-band exhaust, .81 a/r
Tubular Top Mount Manifold
Tial 44 Wastegate
Aluminum Intake manifold w/ front mounted throttle body (Supra style)
MLS .140 head spacer
ARP head studs
Precision 750hp FMIC
3” Intercooler plumbing
Tial 50mm BOV
3” SS Turboback Exhaust
Mocal Oil Cooler with Ireland Engineering Filter cap
Dehrale Power Steering Cooler
AEM Truboost EBC
AEM Uego Wideband
AEM water/meth
MaximumPSI Fuel Rail with 6an feed and return
Aeromotive FPR
Aeromotive 6an inline filter

custom tune by Nick G.

power goal: 500whp on 93 octane, 600+whp on 100 octane & meth

...and on to some pictures:

rough turbo placement (notice the sheet metal that was hammered to make the exhaust side of the turbo fit):

94JZA80 · 09-11-2009, 09:44 PM

beginning fabrication of the exhaust manifold:

...and meth tank fabrication:

ianbiz · 09-11-2009, 09:45 PM

drooooll

94JZA80 · 09-11-2009, 09:51 PM

...more on the exhaust manifold as it comes together:

94JZA80 · 09-11-2009, 09:54 PM

...and now a little more on how the intake manifold you see in some of the first pics came to life:

94JZA80 · 09-11-2009, 10:00 PM

exhaust manifold completely tacked and ready for welding

...by the way, one of the most amazing things about this build is the fact that, while Shawn has been working on cars for quite some time now, this project is the first in which he handled all of the fabrication himself...he basically taught himself to TIG weld on this project, and you'd never know he's that new to welding judging by the welds you'll see shortly:

94JZA80 · 09-11-2009, 10:05 PM

in the mean time, here are some pics of the downpipe:

...and the exhaust from the downpipe back:

94JZA80 · 09-11-2009, 10:14 PM

because of space constraints, the head had to come off in order to install the manifold (likewise, the head would have to come off again to remove the manifold):

...and now on to some of those quality welds

:

...and here's the manifold completely welded and mounted on the head:

...ok, i'm taking a break. more pictures soon...

Citizen Z · 09-11-2009, 10:41 PM

Amazing work. The only downside to that fabrication approach is there isn't any real flow/design analysis. Every thing is done with off the shelf billet/cnc machine parts/stock elbow sections etc. Its pretty much a "make it fit" approach which can produce really inefficient designs, despite the best efforts of a highly experienced craftsman. That said, if you're up against the wall reagards to space, do whatever it takes; that thing'll be a monster no matter how you slice it.

vgame64 · 09-11-2009, 11:30 PM

Looks great!

94JZA80 · 09-12-2009, 02:42 AM

Quote:

Originally Posted by Citizen Z

Amazing work. The only downside to that fabrication approach is there isn't any real flow/design analysis. Every thing is done with off the shelf billet/cnc machine parts/stock elbow sections etc. Its pretty much a "make it fit" approach which can produce really inefficient designs, despite the best efforts of a highly experienced craftsman. That said, if you're up against the wall reagards to space, do whatever it takes; that thing'll be a monster no matter how you slice it.

agreed - that is an unfortunate downside to the space limitations under the hood of the M Coupe. actually, most turbo M Coupes are bottom mount turbos, which allow for a manifold that is better in deisng with respect to flow rates and characteristics. but Brian wanted to be one of the rare M Coupes with a top mount turbo setup. luckily, given his power goals (~500whp on 93 octane and 600+whp on 100 octane & meth), the efficiency, or lack thereof, of the exhaust manifold should not be a limitation or a problem in any way.

94JZA80 · 09-12-2009, 02:49 AM

...more welding up close:

Some more custom fab/relocation:

94JZA80 · 09-12-2009, 02:56 AM

gold foil to reflect heat and protect the sheet metal, chassis welds, and paint from excessive heat cycling:

that's it for tonight...gotta work in the morning.

Citizen Z · 09-12-2009, 01:19 PM

Holy crap. That gold foil + blue =

Curt2000 · 09-12-2009, 03:00 PM

Now That's What I'm Talking Bout!

EdmBimmer · 09-12-2009, 03:02 PM

Another epic build, along with that E30 V10.

Well done guys!

Mooreski · 09-12-2009, 03:25 PM

Subscribed!

I was going to ask if heat from the exhaust side of the turbo was a concern. Based on the gold foil, I'm guessing it is and it's handled.

FifthStreetz · 09-12-2009, 03:33 PM

omg sick, its going to be a beast!

research · 09-12-2009, 04:16 PM

im subscribed now after seeing the frigin gold.

Davin · 09-12-2009, 04:23 PM

good stuff

the infamous... · 09-12-2009, 04:29 PM

Epic indeed!

alq80 · 09-12-2009, 04:35 PM

This nothing short of epic!!!

09-11-2009, 09:40 PM	#1
94JZA80 Captain Drives: 1994 BPU Supra Join Date: Jan 2007 Location: Sarasota, FL Posts: 646 iTrader: (1)	EPIC BUILD!!! - Top Mount PT6262 M Coupe Turbo as the title suggests, my brother Brian has been performing surgery on his 1999 Z3 M Coupe for the past month or so with the help of our good friend and fabricator Shawn of Fifteen52 (1552v2.com). i originally wanted to start this thread back when Brian first started the project, but i just didn't have the time until now. at this point, the build part of the project is essentially done and is just awaiting a tune. however i will do my best to "cut and paste" the pictures and updates from another forum so that you can all see the progress and ask questions. i'm sure some of you are members on one or more of the boards we posted a build thread on (such as bimmerforums.com), and may already be familiar with this particular build. nevertheless, i thought this would be a good place to post it as well, since you 135i and 335i guys are boost junkies too . currently i don't believe either Brian or Shawn are members here, but i will get them to create accounts so they can converse and field questions as well. so without further ado, on to the build... Parts List: Precision PT6262, Billet Wheel, 4” Inlet, 3” V-band exhaust, .81 a/r Tubular Top Mount Manifold Tial 44 Wastegate Aluminum Intake manifold w/ front mounted throttle body (Supra style) MLS .140 head spacer ARP head studs Precision 750hp FMIC 3” Intercooler plumbing Tial 50mm BOV 3” SS Turboback Exhaust Mocal Oil Cooler with Ireland Engineering Filter cap Dehrale Power Steering Cooler AEM Truboost EBC AEM Uego Wideband AEM water/meth MaximumPSI Fuel Rail with 6an feed and return Aeromotive FPR Aeromotive 6an inline filter custom tune by Nick G. power goal: 500whp on 93 octane, 600+whp on 100 octane & meth ...and on to some pictures: rough turbo placement (notice the sheet metal that was hammered to make the exhaust side of the turbo fit): __________________ . Last edited by 94JZA80; 09-12-2009 at 12:19 PM.
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09-11-2009, 09:44 PM	#2
94JZA80 Captain Drives: 1994 BPU Supra Join Date: Jan 2007 Location: Sarasota, FL Posts: 646 iTrader: (1)	beginning fabrication of the exhaust manifold: ...and meth tank fabrication: __________________ .

09-11-2009, 09:45 PM	#3
ianbiz 4th E90 Drives: Black E90 and a SGM E90 Join Date: Jul 2007 Location: Melbourne/UCF, Florida Posts: 4,010 iTrader: (3)	drooooll __________________ Ian

09-11-2009, 09:51 PM	#4
94JZA80 Captain Drives: 1994 BPU Supra Join Date: Jan 2007 Location: Sarasota, FL Posts: 646 iTrader: (1)	...more on the exhaust manifold as it comes together: __________________ .

09-11-2009, 09:54 PM	#5
94JZA80 Captain Drives: 1994 BPU Supra Join Date: Jan 2007 Location: Sarasota, FL Posts: 646 iTrader: (1)	...and now a little more on how the intake manifold you see in some of the first pics came to life: __________________ .

09-11-2009, 10:00 PM	#6
94JZA80 Captain Drives: 1994 BPU Supra Join Date: Jan 2007 Location: Sarasota, FL Posts: 646 iTrader: (1)	exhaust manifold completely tacked and ready for welding ...by the way, one of the most amazing things about this build is the fact that, while Shawn has been working on cars for quite some time now, this project is the first in which he handled all of the fabrication himself...he basically taught himself to TIG weld on this project, and you'd never know he's that new to welding judging by the welds you'll see shortly: __________________ .

09-11-2009, 10:05 PM	#7
94JZA80 Captain Drives: 1994 BPU Supra Join Date: Jan 2007 Location: Sarasota, FL Posts: 646 iTrader: (1)	in the mean time, here are some pics of the downpipe: ...and the exhaust from the downpipe back: __________________ .

09-11-2009, 10:14 PM	#8
94JZA80 Captain Drives: 1994 BPU Supra Join Date: Jan 2007 Location: Sarasota, FL Posts: 646 iTrader: (1)	because of space constraints, the head had to come off in order to install the manifold (likewise, the head would have to come off again to remove the manifold): ...and now on to some of those quality welds : ...and here's the manifold completely welded and mounted on the head: ...ok, i'm taking a break. more pictures soon... __________________ .

09-11-2009, 10:41 PM	#9
Citizen Z Alpine Master Drives: '08 135i AW Sport Join Date: May 2008 Location: Kansas Posts: 1,316 iTrader: (0)	Amazing work. The only downside to that fabrication approach is there isn't any real flow/design analysis. Every thing is done with off the shelf billet/cnc machine parts/stock elbow sections etc. Its pretty much a "make it fit" approach which can produce really inefficient designs, despite the best efforts of a highly experienced craftsman. That said, if you're up against the wall reagards to space, do whatever it takes; that thing'll be a monster no matter how you slice it. __________________ Alpine White with Taupe Leather 135i, Sports Package, Heated Seats, Comfort Access, iPod Adapter Fastness: http://www.1addicts.com/forums/showthread.php?t=252727

09-11-2009, 11:30 PM	#10
vgame64 Colonel Drives: 4 wheels, engine Join Date: Jul 2008 Location: USA Posts: 2,454 iTrader: (9)	Looks great!

09-12-2009, 02:49 AM	#12
94JZA80 Captain Drives: 1994 BPU Supra Join Date: Jan 2007 Location: Sarasota, FL Posts: 646 iTrader: (1)	...more welding up close: Some more custom fab/relocation: __________________ .

09-12-2009, 02:56 AM	#13
94JZA80 Captain Drives: 1994 BPU Supra Join Date: Jan 2007 Location: Sarasota, FL Posts: 646 iTrader: (1)	gold foil to reflect heat and protect the sheet metal, chassis welds, and paint from excessive heat cycling: that's it for tonight...gotta work in the morning. __________________ .

09-12-2009, 01:19 PM	#14
Citizen Z Alpine Master Drives: '08 135i AW Sport Join Date: May 2008 Location: Kansas Posts: 1,316 iTrader: (0)	Holy crap. That gold foil + blue = __________________ Alpine White with Taupe Leather 135i, Sports Package, Heated Seats, Comfort Access, iPod Adapter Fastness: http://www.1addicts.com/forums/showthread.php?t=252727

09-12-2009, 03:00 PM	#15
Curt2000 Captain Drives: M-Sport Alpine N54 E93 Join Date: Jun 2007 Location: Ohio Posts: 957 iTrader: (10)	Now That's What I'm Talking Bout! __________________ *His: 2010 AW E93 335i Autobot Hers: 2009 JB 135i*

09-12-2009, 03:02 PM	#16
EdmBimmer First Lieutenant Drives: '08 535i Join Date: Sep 2006 Location: Edmonton Posts: 397 iTrader: (4)	Another epic build, along with that E30 V10. Well done guys! __________________ In the Garage '10 E70 X5d Alpine White LOADED UP - '09 Dodge Journey SXT AWD Bright Silver (Free Work Ride) RIP '08 BMW E60 535i - '06 BMW E90 330i - '05 Acura EL - '98 Honda Prelude - '99 Audi A4 - '02 Honda Civic - '06 Nissan Xterra

09-12-2009, 03:25 PM	#17
Mooreski Lieutenant Drives: AW '08 E92 335i Join Date: Sep 2007 Location: Portland, OR Posts: 448 iTrader: (0)	Subscribed! I was going to ask if heat from the exhaust side of the turbo was a concern. Based on the gold foil, I'm guessing it is and it's handled.

09-12-2009, 03:33 PM	#18
FifthStreetz O! So Sour!! Drives: E92 M3 Join Date: Apr 2007 Location: Fort Lee, NJ Posts: 14,831 iTrader: (17) View FifthStreetz's Garage	omg sick, its going to be a beast! __________________

09-12-2009, 04:16 PM	#19
research Brigadier General Drives: 320d E90 Join Date: Sep 2007 Location: Estonia Posts: 3,577 iTrader: (1) View research's Garage	im subscribed now after seeing the frigin gold. __________________ ∑ 2006 BMW E90 320dA Titanium Silver: OEM 161 17" \| Michelin Pilot Sport PS2 \| Matte Black Grilles \| CF interior wrap

09-12-2009, 04:23 PM	#20
Davin Major Drives: BMW 530i M-Sport Join Date: Mar 2008 Location: Trinidad & Tobago Posts: 1,178 iTrader: (0)	good stuff

09-12-2009, 04:29 PM	#21
the infamous... Enthusiastic Enthusiast Drives: on PZero Nero's Join Date: Jul 2008 Location: Coral Springs, FL Posts: 4,792 iTrader: (0)	Epic indeed! __________________ Bimmerpost 4Life /// Joy is DSC OFF ///iND ///eAs ///WSTO ///LTBMW ///ActiveAutowerke

09-12-2009, 04:35 PM	#22
alq80 Lieutenant Drives: E92 335i Join Date: Dec 2007 Location: PA / Kuwait Posts: 440 iTrader: (0)	This nothing short of epic!!! __________________ 335i . Montego Blue . HKS Exhaust .