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BMW 3-Series (E90 E92) Forum > E90 / E92 / E93 3-series Powertrain and Drivetrain Discussions > N54 Turbo Engine / Drivetrain / Exhaust Modifications - 335i > Designing a lower cost, higher performance oil cooler solution



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      03-11-2013, 06:19 AM   #67
ashmostro
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UPDATE:

So as some know this project was put on temporary hold as it seemed that my car had developed a super secret oil leak based on consumption rate so I have been tracking consumption at the recommendation of my dealer. Well, I have yet to add another quart of oil since the last and while that has only been about 700 miles I feel comfortable that part of the problem was driving style (lots of stop and go traffic on my commute). I've intentionally been flogging it more whenever I can which I think has helped.

Anyway, this weekend I went ahead and took the front down to develop a game plan for the bracketry and feel I have a good basis for a design, which I'm going to draw up and send to my fab shop to prototype. It may need tweaking after initial fitting but I'm hoping I get it close to right the first time.

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I also am working on a brake duct backing plate that- if it fits well- I'll consider selling as a standalone part rather than a full kit (you source your own intake duct, since different cars will require a different intake location and style). I'm going to try to use the stock duct location as an intake (I removed the useless factory ducts completely).

Depending on fab cost for the backing plate, I'm hoping pricing will come in at hundreds less than the competition while being extremely effective. And yes, the duct exit will be aimed at the inner hub, not the rotor face.

Will update again when I have new info.
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      03-11-2013, 05:01 PM   #68
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out of curiousity, what are you doing to secure the bracket to the frame?
are you using the sandwich method (between bumper and frame) that OEM oil cooler uses?
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      03-11-2013, 05:40 PM   #69
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Great question. The mounting frankly is the only real challenge in the design everything else is pretty trivial.

I'm purposely using as much of the stock mounting locations and bracketry as possible. That means I will build a bracket that leverages the factory side mount, and another that attaches to the triangulated top mount. I think its important to use the top mount too because it really ttightens up the vibrations and potential fatigue vs just the side mount alone. Oil coolers don't like vibration.
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      03-11-2013, 05:42 PM   #70
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unfortunately, people without OEM cooler like myself will not have the stock mounting locations (the side mount and the top mount).
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      03-11-2013, 06:53 PM   #71
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Hmm, didn't realize the mount points wouldn't even exist. Would have to think on that. Thanks for letting me know...
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      03-11-2013, 11:06 PM   #72
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Quote:
Originally Posted by ashmostro View Post
Hmm, didn't realize the mount points wouldn't even exist. Would have to think on that. Thanks for letting me know...
you're welcome. hope I'm not too late. if you look at stetts, you'll see that they use a stand alone bracket. unfortunately they will not sell just the bracket.
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      03-11-2013, 11:10 PM   #73
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Yeah I was originally going in the same direction but I don't like how the other end of the cooler is left unsupported. That's why I want to use the factory top mount to significantly reduce play, which is important in a high-G application.

I will likely have to look at the non-oil cooler equipped cars as a second phase. Mind if I ping you offline for more info on what your fender well area looks like?

Last edited by ashmostro; 03-12-2013 at 06:50 AM.
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      03-11-2013, 11:20 PM   #74
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sure thing. I've taken a bunch of high res pics of my front area. I'm just worried that the differences are to great that it's impractical to modify the version 1.
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      03-12-2013, 06:50 AM   #75
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PMed you my email address
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      03-12-2013, 11:13 AM   #76
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Quote:
Originally Posted by 335okc View Post
unfortunately, people without OEM cooler like myself will not have the stock mounting locations (the side mount and the top mount).

^ You can do it...it's just a little more involved. You need to remove the front bumper and steel push bar then install the factory mounting hardware.

I'm in the same situation. I have the factory hardware, I just need to install it.
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      03-12-2013, 11:19 AM   #77
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Helpful to know... So i will spec that those parts need to be purchased for non oil cooler cars. Thanks
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      03-12-2013, 05:47 PM   #78
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Quote:
Originally Posted by SalemChiro View Post
^ You can do it...it's just a little more involved. You need to remove the front bumper and steel push bar then install the factory mounting hardware.

I'm in the same situation. I have the factory hardware, I just need to install it.
How much do those cost to you? last i checked i couldn't get the top triangle part without buying the whole cooler.

In my honest opinion, this solution (factory hardware + custom design bracket) isn't the most elegant. if someone is taking the time to custom design something, there's no reason to spend the money on factory hardware too. but that's just my 2cents.

i believe ER has this kind of solution because they have to fabricate this custom bracket for the other side (on their dual oil cooler setup)
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      03-12-2013, 06:44 PM   #79
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I hear you on that. As i said i didn't consider that the mounting points wouldn't even exist on non cooler cars. Will continue to think about the solution as i haven't started the fabrication yet. thanks for the pics too!
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      03-21-2013, 09:12 AM   #80
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would you be willing to look at creating a mount for the drivers side as well? So we can make a DIY dual cooler setup for us Southern folk.
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      03-22-2013, 05:15 AM   #81
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Perhaps as a followup, I think. I have a feeling the mount areas are symmetric and since I have a 335is I can compare the auxiliary radiator to the stock cooler.

I can't promise a positive result but I will at least investigate it.
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      03-22-2013, 09:00 AM   #82
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Appreciate it, looking forward to your findings.
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      04-18-2013, 07:25 AM   #83
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Quote:
Originally Posted by ashmostro View Post
Perhaps as a followup, I think. I have a feeling the mount areas are symmetric and since I have a 335is I can compare the auxiliary radiator to the stock cooler.

I can't promise a positive result but I will at least investigate it.
ash, any update?
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      04-18-2013, 01:00 PM   #84
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Yes in fact.

I have designed the brackets but my sheet metal guy says he doesn't have the right bending breaks to do the bends I need. I am now researching other guys to use, or I will invest in my own bending break and just do all the bends myself.

The other good news is, due to a change in the design I just made, I think I might be able to build an air guide as some of you have requested. I won't do that right away though because I want to get the fitment set up first.

Development has been slow lately because I've been traveling every week for work- from NY, to DC, to New Orleans, and then off to Texas, and NJ later on.

I'm giving myself a drop-dead date to get this done of end of May as I'm a) getting married in early June and b) have a trackday in late June I want this to be all ready for.

So, sorry for the slow development time, but since I'm doing this entirely of my own personal finances and spare time, I have to prioritize accordingly.
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      04-18-2013, 01:16 PM   #85
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Quote:
Originally Posted by ashmostro View Post
Yes in fact.

I have designed the brackets but my sheet metal guy says he doesn't have the right bending breaks to do the bends I need. I am now researching other guys to use, or I will invest in my own bending break and just do all the bends myself.

The other good news is, due to a change in the design I just made, I think I might be able to build an air guide as some of you have requested. I won't do that right away though because I want to get the fitment set up first.

Development has been slow lately because I've been traveling every week for work- from NY, to DC, to New Orleans, and then off to Texas, and NJ later on.

I'm giving myself a drop-dead date to get this done of end of May as I'm a) getting married in early June and b) have a trackday in late June I want this to be all ready for.

So, sorry for the slow development time, but since I'm doing this entirely of my own personal finances and spare time, I have to prioritize accordingly.
Send me a small drawing or dimensions. I'm pretty sure the guys in the shop (aerospace industry) can do it for me and I'l send it your way. And that way I get one for myself
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      04-18-2013, 01:18 PM   #86
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Sweet! I have to redraw my latest CAD drawing to accommodate the design change, so it might be a day or two.

PM me your email address bud.

Yay for crowd sourcing!
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      04-19-2013, 10:29 AM   #87
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thanks for the update ash, and it's always good to have a time frame
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      04-20-2013, 01:51 PM   #88
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Quote:
Originally Posted by Bimmer305 View Post
Send me a small drawing or dimensions. I'm pretty sure the guys in the shop (aerospace industry) can do it for me and I'l send it your way. And that way I get one for myself

You've got mail bud!
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