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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 > Batch2 progress - Logging / Fuel system update



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      10-02-2013, 04:20 PM   #1
Tony@vargasturbotech
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Batch2 progress - Logging / Fuel system update

Just a little snippet of the things we are doing over here...

Fun Fact: During spool up from 1750-2750 the turbo shaft speed goes up 89,056 in 1000 RPM...
That was from an OTS map at 12 psi, we start tuning tonight...

Fuel System update:

We also basically completely removed the stock LPFP fuel system from the fueling loop, we are running the walbro 455 intank, across to the drivers tank which has the stock regulator completely removed, that feeds a custom surge tank fitted with a bosch 044 inline pump sitting inside the surge tank for cooling and lowered sound levels, this feeds to a real aftermarket regulator, which is boost dependent and adds 1 psi of pressure for every psi of boost, this is regulated by a return line back to the surge tank, basically turning it into a return style system. From the surge tank forward, and the returns are Aeroquip -6 push loc hose rated at over 500 PSI. So far the system seems to be working flawlessly. We will see how it does once we get some real HP asking for fuel.

Is this needed for stock frames? Not at all, but we are in the works of building a motor and this will be needed for 800+ WHP. So we just like to do it once.
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Last edited by Tony@vargasturbotech; 10-02-2013 at 05:19 PM.
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      10-02-2013, 04:21 PM   #2
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Monitoring all that is awesome, nice job
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      10-02-2013, 04:28 PM   #3
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Subscribed for the following whp numbers:

18lbs stage 2 on 93 octane
19lbs race map on 100 octane

Thanks
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      10-02-2013, 04:30 PM   #4
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I'm liking the turbo shaft speed display.
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      10-02-2013, 04:32 PM   #5
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Subscribed !
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      10-02-2013, 04:33 PM   #6
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Itís a bummer we wonít be able to benchmark these figures since Tony is the first to grab this data and post itÖbut regardless thank you for doing that. Eager to see power figures when the tuning is all squared away.
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      10-02-2013, 05:43 PM   #7
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Awesome work thus far. I can't wait to see the end results.
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      10-02-2013, 06:25 PM   #8
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One question: when is gonna be out?
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      10-02-2013, 08:59 PM   #9
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Nice. 45 lb/min at 12 psi.
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      10-02-2013, 09:19 PM   #10
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Good update Tony!
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      10-02-2013, 09:22 PM   #11
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Quote:
Originally Posted by Aerotest View Post
Nice. 45 lb/min at 12 psi.
Don't put any stock in that Maf yet, its not calibrated quite right, its out of an STI and we are still playing with it to get it right, its maxing out at 5 volts way too early. But everything else is spot on, we have EGT on the gauge but actually have to run another thermocouple to log it as the one for our gauge is not compatible with the amplifier you have to use to log it.
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      10-02-2013, 09:43 PM   #12
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Ah, I was going to ask why MAF was maxing. Good stuff, very interesting!
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      10-02-2013, 10:22 PM   #13
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That's the exact fuel system i designed and partially installed. While i was testing a short version of it the diaphragm blew inside the fpr. I had it set at 75psi with the 1:1 hooked up. After boosting the fpr didn't like it much. I was using a fuel lab which i believe is rated to 85psi. I also have a aero that is rated to 100 i believe. I ran a -6 adapted to the stock hpfp inlet with a adapter for the lpfp sensor. I really need someone to design a - 8 feed and - 6 return fuel hat.
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      10-02-2013, 10:28 PM   #14
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Quote:
Originally Posted by 3000GT MR
That's the exact fuel system i designed and partially installed. While i was testing a short version of it the diaphragm blew inside the fpr. I had it set at 75psi with the 1:1 hooked up. After boosting the fpr didn't like it much. I was using a fuel lab which i believe is rated to 85psi. I also have a aero that is rated to 100 i believe. I ran a -6 adapted to the stock hpfp inlet with a adapter for the lpfp sensor. I really need someone to design a - 8 feed and - 6 return fuel hat.
You need to use at least a 100 psi regulator, mine is consistently running over 100 psi when in boost. From where it goes from plastic to the rubber hose right below the fuel pressure sensor, that is 500 psi fuel line as well, I just taped into that with my pushloc, and got rid of the plastic. So far it seems to be performing pretty well. This isn't anything, this how we run fuel systems for 90% of high performance turbo cats we build, this fuel system just has it's little quirks.
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      10-02-2013, 10:59 PM   #15
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you left out the painful DME update we did to get this project kick started.
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      10-02-2013, 11:01 PM   #16
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Quote:
Originally Posted by Wedge1967 View Post
you left out the painful DME update we did to get this project kick started.
Oh yeah, the 3 day DME flash.. hahahaha. I just texted you, but don't worry about answering, I reinstalled the cobb and that code is gone..
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      10-02-2013, 11:06 PM   #17
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Quote:
Originally Posted by Vargasturbotech
Quote:
Originally Posted by 3000GT MR
That's the exact fuel system i designed and partially installed. While i was testing a short version of it the diaphragm blew inside the fpr. I had it set at 75psi with the 1:1 hooked up. After boosting the fpr didn't like it much. I was using a fuel lab which i believe is rated to 85psi. I also have a aero that is rated to 100 i believe. I ran a -6 adapted to the stock hpfp inlet with a adapter for the lpfp sensor. I really need someone to design a - 8 feed and - 6 return fuel hat.
You need to use at least a 100 psi regulator, mine is consistently running over 100 psi when in boost. From where it goes from plastic to the rubber hose right below the fuel pressure sensor, that is 500 psi fuel line as well, I just taped into that with my pushloc, and got rid of the plastic. So far it seems to be performing pretty well. This isn't anything, this how we run fuel systems for 90% of high performance turbo cats we build, this fuel system just has it's little quirks.
Yea i ended up modding the pushloc. I just like machined parts. It gives me a warm and fuzzy
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      10-02-2013, 11:16 PM   #18
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Quote:
Originally Posted by Vargasturbotech View Post
Oh yeah, the 3 day DME flash.. hahahaha. I just texted you, but don't worry about answering, I reinstalled the cobb and that code is gone..
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      10-03-2013, 06:11 AM   #19
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Quote:
Originally Posted by Vargasturbotech View Post
Don't put any stock in that Maf yet, its not calibrated quite right, its out of an STI and we are still playing with it to get it right, its maxing out at 5 volts way too early. But everything else is spot on, we have EGT on the gauge but actually have to run another thermocouple to log it as the one for our gauge is not compatible with the amplifier you have to use to log it.
It is going to difficult to calibrate the MAF curve without it being in the fueling logic loop. Pls let us know what you come up with for a method, would be a good learning point. You will be setting the standard by providing airflow data for your upgrade.
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      10-03-2013, 08:40 AM   #20
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Quote:
Originally Posted by Aerotest View Post
It is going to difficult to calibrate the MAF curve without it being in the fueling logic loop. Pls let us know what you come up with for a method, would be a good learning point. You will be setting the standard by providing airflow data for your upgrade.
The problem right now is, its maxing at 5 volts and everything I have read says 5 volts on those is like 400 WHP, which would make sense, we may have to use a bigger one, even though I was told these can handle over 500 WHP.
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      10-03-2013, 09:16 AM   #21
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Tony, I really don't understand why you modified the fueling system so much. Sure, for folks who want to max out these turbos, it makes sense, but your average buyer isn't looking to go in at stage 2 turbo price levels if the attached strings include buying and installing all your new fueling equipment. Plus, all your whp numbers would be with this fuel upgrade. I'm intersted in seeing the numbers on stock fueling system vs oem turbos.
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      10-03-2013, 09:26 AM   #22
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Quote:
Originally Posted by Killerfish2012 View Post
Tony, I really don't understand why you modified the fueling system so much. Sure, for folks who want to max out these turbos, it makes sense, but your average buyer isn't looking to go in at stage 2 turbo price levels if the attached strings include buying and installing all your new fueling equipment. Plus, all your whp numbers would be with this fuel upgrade. I'm intersted in seeing the numbers on stock fueling system vs oem turbos.
Might want to do a bit of research, cause I'm not sure you really understand how a fuel system works (not meant as a jab, just stating facts). They add zero power, ZERO. Its like octane, you can put as much race gas in the tank as you want, and its not going to give you anymore power, all it does it give you the ability to make power safely. An upgraded fuel system does not change anything at all performance wise. Its just making sure we will have fuel when we need it in the future. We all know stock frames are fine with a LPFP upgrade and some meth, running straight E85 you might be running out of fuel a little bit. We just got the shop car ready for the bigger things to come. I am not going to keep our fuel system stock, so we can test and be like guess what guys, you need to upgrade your lpfp, we are out of fuel. That's already been established. We are looking at what the turbos can do with the well known fuel limitations removed. Pretty simple
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