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BMW 3-Series (E90 E92) Forum > BMW E90/E92/E93 3-series General Forums > Regional Forums > UK > UK Technical Forum > 335i Turbos - Stage 2 now installed and reviewed!!



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      03-21-2010, 09:54 PM   #243
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Quote:
Originally Posted by dlbrooks18 View Post
fair enough, this looks very promising
It is hugely promising!! I'll have more news over the next few days
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      03-21-2010, 10:00 PM   #244
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awesome, thanks for the update.
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      03-22-2010, 04:27 AM   #245
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WOW this is very sweet! lol!

I can't wait 4 the end result!
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      03-22-2010, 06:10 AM   #246
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Great stuff Tony

Can't wait to here the final results!

Judging by the international audience on this thread, it seems you are really leading the way with this development work....
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      03-22-2010, 01:14 PM   #247
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So, Tony, how much power was your car actually producing with the Stage 1 turbo upgrade??
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      03-22-2010, 08:45 PM   #248
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so they are plan to offer stage 1 and 2 with different pricing?
with stage 1, WG rattle still be fixed right?
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      03-22-2010, 11:19 PM   #249
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Quote:
Originally Posted by a1reader View Post
So, Tony, how much power was your car actually producing with the Stage 1 turbo upgrade??
Just about 500bhp at the flywheel and 480lbft torque
A lot of that is down to the supporting mods as well though

I was running a detuned version of the mapping, purely for daily driving, and that had around 470bhp or so.
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      03-22-2010, 11:20 PM   #250
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Quote:
Originally Posted by hun77777 View Post
so they are plan to offer stage 1 and 2 with different pricing?
with stage 1, WG rattle still be fixed right?
Correct. Both Stage 1 and Stage 2 products will be offered. WG rattle is fixed in both cases.
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      03-23-2010, 12:50 AM   #251
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Quote:
Originally Posted by E92Fan View Post
Correct. Both Stage 1 and Stage 2 products will be offered. WG rattle is fixed in both cases.
how much does the stage 1 cost? I have pair of 335i turbos in my garage and Im thinking to get them upgraded
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      03-23-2010, 02:13 AM   #252
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Quote:
Originally Posted by E92Fan View Post
Just about 500bhp at the flywheel and 480lbft torque
A lot of that is down to the supporting mods as well though

I was running a detuned version of the mapping, purely for daily driving, and that had around 470bhp or so.
Must be an absolute MONSTER!!! How is the transmission taking all that torque, and do you have any idea if the DCT box can handle the increased torque??
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      03-23-2010, 03:31 AM   #253
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Quote:
Originally Posted by a1reader View Post
Must be an absolute MONSTER!!! How is the transmission taking all that torque, and do you have any idea if the DCT box can handle the increased torque??
Transmission handles it fine - there's torque tapering in the mapping to smooth out gearchanges and to prevent the transmission from blowing up. Once the car is on the move the amount of torque isn't really an issue.

The DCT can't handle the same amount of torque as the regular ZF automatic gearbox. I suggest the maximum safe torque number for the DCT box to handle will be approximately 500Nm
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      03-23-2010, 04:01 AM   #254
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Talking Stage 2 Turbos finished!

Stage 2 turbos now finished and ready for installation!



Finished Turbos - Stage 2

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Compressor Wheel - Stage 2
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Turbine Wheel - Stage 2
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Turbine Housing & Wheel - Stage 2
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Turbo & Manifold - Stage 2
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      03-23-2010, 04:40 AM   #255
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07 335i AT - TD St.2 Turbos - COBB (Custom Cobb mapping by http://www.protuningfreaks.com/) - JB4G5 ISO - Okada Coils - NGK 5992 Plugs - E85 Walbro - Injen Intake - Helix IC - Snow Stg. 3 - Stett CP - AR DPs - midpipes 100 HJS Cats - Bastuck Quad - PSS10 - QUAIFE LSD - BMS OCC - Forge DVs - AR OC - ALCON BBK - M3 Chassi - Dinan CP - Velocity M rear Toe arms - Advan RZ-DF - Level 10 AT upgrade - Alpina AT Flash
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      03-23-2010, 05:16 AM   #256
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nice.. wish we had a stock turbo for a side by side comparison though. it's hard to put into perspective.
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      03-23-2010, 05:38 AM   #257
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Quote:
Originally Posted by JoeyFiasco View Post
nice.. wish we had a stock turbo for a side by side comparison though. it's hard to put into perspective.

The two pictures below show how much larger the new Stage 2 Turbine Wheel is over the Stage 1 version, which in itself is a clipped and reprofiled original sized wheel.


Stage 1 Turbine Wheel - clipped and reprofiled original
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Stage 2 Turbine Wheel - larger and custom installed
Name:  Turbine Wheel.jpg
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      03-23-2010, 05:48 AM   #258
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much easier to see the difference
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      03-23-2010, 06:13 AM   #259
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Quote:
Originally Posted by E92Fan View Post
Transmission handles it fine - there's torque tapering in the mapping to smooth out gearchanges and to prevent the transmission from blowing up. Once the car is on the move the amount of torque isn't really an issue.

The DCT can't handle the same amount of torque as the regular ZF automatic gearbox. I suggest the maximum safe torque number for the DCT box to handle will be approximately 500Nm
Great pictures and upgrades, all this project is so usefull for all of US!!!!
Could you post more pictures of the wastegate actuator linkage and the bushing?
Are your turbos the old type? How did you upgraded to the 8mm actuators if BMW don't sell them?

What about the 6 Manual max torque?
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      03-23-2010, 07:00 AM   #260
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Quote:
Originally Posted by marconi118 View Post
Great pictures and upgrades, all this project is so usefull for all of US!!!!
Could you post more pictures of the wastegate actuator linkage and the bushing?
Are your turbos the old type? How did you upgraded to the 8mm actuators if BMW don't sell them?

What about the 6 Manual max torque?

The picture of the new bushing is on Page 3 of this thread, but I'll post it again here. I'll post a separate pic of the wastegate linkages in a short while.

The turbos are the original OEM units - I have 8mm actuators because I am persuasive and I have good friends in helpful places!!!

6MT - problem isn't so much the gearbox, as the clutch and flywheel. I wouldn't put much more than 500Nm through that, although it depends very much on the driver and the driving style. If you treat the gearbox and clutch like a caveman, even 450Nm won't last very long!

Name:  New wastegate bush, machined from stainless billett - small.jpg
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Size:  345.0 KB
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      03-23-2010, 07:05 AM   #261
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Quote:
Originally Posted by E92Fan View Post
The DCT can't handle the same amount of torque as the regular ZF automatic gearbox. I suggest the maximum safe torque number for the DCT box to handle will be approximately 500Nm
Looking good Tony!

I heard the DCT can handle up to 600Nm (mentioned by Getrag)
500Nm sounds low to me, as the 335Is with DCT is having 450Nm with 500Nm during overboost.
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      03-23-2010, 07:53 AM   #262
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Quote:
Originally Posted by marcel b View Post
Looking good Tony!

I heard the DCT can handle up to 600Nm (mentioned by Getrag)
500Nm sounds low to me, as the 335Is with DCT is having 450Nm with 500Nm during overboost.

Very good point Marcel - I stand corrected!
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      03-23-2010, 08:01 AM   #263
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More images as requested




New wastegate linkage
Name:  _DSC8351.JPG
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Stage 2 turbine wheel
Name:  _DSC8357.JPG
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Stage 2 compressor wheel
Name:  _DSC8360.JPG
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Size:  376.7 KB
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      03-23-2010, 08:33 AM   #264
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Stop Putting All These Pictures!!!!!

I am drooling behind my desk and completely distracted! I am really curious what the final 2 solutions are and what the prices are.

I guess upgraded turbo's only make sense with reprog / piggy bag and will not bring much on a 335 with Powerkit and FMIC only? (standard DP etc)

Would a dealer see the difference between a standard and a stage 1 turbo when you bring in the car for maintenance?
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