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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 > Downpipe has warped flange on the turbo side



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      11-21-2010, 12:05 PM   #1
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Downpipe has warped flange on the turbo side

The downpipes are VK and for the time being they are for all intents and purposes defunct due to legal issues. The problem is that the front pipe, when trying to line up to the turbo, will be flush on the bottom but have a 1/8" or so gap on the top - too large for the clamp to compensate for.

So I took the pipe down and found this:

Picture of the gap:



(May be hard to see but the majority of the flange is sitting on a flat surface, you can see there is a gap with both the part that goes inside and the flange the clamp connects too

Here is how the flush "correct" part sits:



Notice it is a few MM lower than the defect.

So for the time being the car is on the rack, job 3/4 complete. I could

A) Undo everything and put the stock DPs back, hoping one day VK's legal problems will be resolved and address the defect then.

-or-

B) Bring the pipes to a metal fabricator and see if they can do anything with them. This is what info I am after - has anyone here had this or a similar problem and have they ever resolved it short of getting a replacement DP?

The nature of the "bend" to me seems like someone dropped the pipe while it was still hot - I know plenty of people are running the VK pipes without fitment defects. Is it possible to heat the pipe back up and pound it to where it's correct?

Any other ideas - what would you guys do?
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      11-21-2010, 12:37 PM   #2
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I'd write those pipes off and get a set from another vendor. Preferrably a higher quality dp. These clearly aren't correct and could be an anomaly but if it were me I wouldn't try this brand again.
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      11-21-2010, 12:40 PM   #3
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Quote:
Originally Posted by forza1976 View Post
I'd write those pipes off and get a set from another vendor. Preferrably a higher quality dp. These clearly aren't correct and could be an anomaly but if it were me I wouldn't try this brand again.
Yea - I realize they are not one of the "best" respected pipes but only bought them since I got them locally and in searching I didn't see anyone posting an quality issues. I'll give it another shot today but I'm afraid I may have to do exactly what you said...
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      11-21-2010, 12:48 PM   #4
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Quote:
Originally Posted by BTM View Post
Yea - I realize they are not one of the "best" respected pipes but only bought them since I got them locally and in searching I didn't see anyone posting an quality issues. I'll give it another shot today but I'm afraid I may have to do exactly what you said...
Anyway to put the flange on a grinder to maybe even it out? Might be a last resort option but something to think about.

Hope it gets worked out, that's a lot of work to find out they don't quite fit when the car is on the rack.
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      11-21-2010, 02:54 PM   #5
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OK - here's what's happening. Because the flange is warped, the opening is no longer circular - it's an oval. I measured the stock pipe vs. the new one and at it's widest the new on is visibly larger, about 1/16". So that's the end of these I guess.
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      11-21-2010, 04:39 PM   #6
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I remember seeing pictures of raceland's DPs and they had the same problem. Not sure if thats fixable, I hope you get it figured out OP.
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      11-21-2010, 04:51 PM   #7
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I think forza has the best approach - just go with new, quality pipes and don't throw any more money at these that could be going toward a nice set of AR pipes...
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      11-21-2010, 06:47 PM   #8
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Quote:
Originally Posted by Bakeme521 View Post
I remember seeing pictures of raceland's DPs and they had the same problem. Not sure if thats fixable, I hope you get it figured out OP.
From my understanding raceland = VK so thats not surprising.. I would just pickup a set of ar design pipes or grab one of these as there is a group buy going on now! The amount of time and money you are going to try and get these to work is not worth it IMO... Better off writing these off to the recycling yard.

http://www.e90post.com/forums/showthread.php?t=455996

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      11-21-2010, 06:48 PM   #9
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This is one reason why I wouldnt mind paying the extra money for the more expensive DPs out there that are proven to fit...I can just imagine the frustration of installing it and then find out that there is a defect on fitment...I would be pissed off beyond belief!
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      11-21-2010, 07:44 PM   #10
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Brian,

You can take them to a metal working shop and have them shave 2mm off the flange so that it sits flush on a flat surface. No big deal at all.

Also, make sure you get brand new sealing gaskets for the turbo flanges. Most people do not replace them when they switch downpipes and in the majority of the cases it works fine. I did not want to take the risk, so I bought new ones for $16.00. It helps me sleep better at night knowing that they are not leaking exhaust gases.
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      11-21-2010, 07:47 PM   #11
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he fixed it last i heard!
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      11-21-2010, 09:03 PM   #12
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Mark's right - I got it to work. Posting from the app so forgive me being frank but I basically was able to grind the part that goes inside the turbo to be perpendicular to the horizontal surface all the way around and had to grind a little of the flange down and it fit nearly perfect. Only drove it shortly (but long enough to get ses lol) but the response is greatly improved and there are no rattles or smell or anything, just slightly louder (which I welcome). The only strange thing is it may be a factor of me driving another car the last 2 days but it does seem to pull right more than I remember - perhaps just time for an alignment.
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      11-21-2010, 09:06 PM   #13
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All said and done, however - you get what you pay for! This took me 2 days and about 14hrs (Internet research included) to get right. And I had the luxury of a rack, compressed air, and just about every tool craftsman makes at my disposal. Were I to do it over, I would gladly shell out for macht snell or ar and have had this wrapped up in 4 hrs or so
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      11-22-2010, 09:53 PM   #14
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should have gotten AA dp's like your boy
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