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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 > N54 -> B58 coil conversion fat bunny adapter plate project



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      04-06-2021, 08:47 PM   #1
rbryantaz
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N54 -> B58 coil conversion fat bunny adapter plate project

Hi everyone,

I have done some coil on plug plate conversions in the past for other platforms.

After seeing that the B58 engine coils are affordable, readily available, and appear to be an upgrade to the n54 I started playing around with them. I just got my prototype back from the waterjet shop today.


I plan on finishing up this weekend but here is a sneak preview:

With the N54 doing a small plate per coil seems to work out well. I could do a bigger single plate but it just seems like it would be harder to deal with if removing a single coil, etc. The shape of the plate I had in mind also just naturally turned out amusing.

I didn't even notice what it resembled until I rendered the drawing for the first time...

The Fat Bunny, (Yes it was designed just before Easter weekend)
Name:  Fat Bunny Plate.jpg
Views: 4927
Size:  89.8 KB

Installed pics:

The plate uses a threaded standoff of the appropriate height, it uses the existing valve cover hole with a self threading plastic screw to hold it in place.
Name:  Fat Bunny Plates installed 1.jpg
Views: 5677
Size:  144.9 KB


The boot is replaced with a rubber one from a different application. It is connected to the coil with a modified spring. The B58 coils have a 1k ohm RFI resistor. My plan is to skip that and rely on the spark plug resistor.

The hole in the plate was made just big enough to fit the coil boot between it and the spark plug tube lip.

I tested the clearance with connector on the Cyl. 1 coil with the engine cover on with a tin foil ball and it is close but fits fine. I had a 3/8" or so thick not fully compressed bit of foil after putting it on and pushing down.

Name:  Fat Bunny Plates installed 2.jpg
Views: 5012
Size:  156.6 KB


Does anyone know if the 1k ohm resistor will be needed? I may be able to source one from a different plug boot like a Nissan or other BMW but it just means one more part to buy for the conversion.

The ground wires weren't long enough to reach cylinder 1 so I made new ones. I am using just the connectors so it really isn't extra work to just make new ones with a ring terminal and some spare brown wire.

I think the other two wires should be long enough to put a terminal on but I could also splice/solder on extended wires for some extra length if needed.

-Rich
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      04-06-2021, 08:55 PM   #2
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Good idea, another company just started doing this conversion kit also. They said a custom boot is needed for the coils, check out their thread for ideas/info maybe;

Take out the spaces and change zeros
00 = oo Zeros equal oh's

https://www.sp 00 lstreet.com/threads/nexsys-motorsport-n54-ignition-coil-upgrade-kit.7170/
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      04-06-2021, 09:11 PM   #3
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Quote:
Originally Posted by IllSic_Design View Post
Good idea, another company just started doing this conversion kit also. They said a custom boot is needed for the coils, check out their thread for ideas/info maybe;

Take out the spaces and change zeros
00 = oo Zeros equal oh's

https://www.sp 00 lstreet.com/threads/nexsys-motorsport-n54-ignition-coil-upgrade-kit.7170/
I am using a rubber boot from another application.

The spring does have to be extended a bit and the end snipped off and formed into a smaller spiral to engage.

Here is a pic of the boot I am using. It is about 3-4mm shorter than the original but it covers the spark plug fine and has plenty of range on the spring.

Name:  coil boot.jpg
Views: 4664
Size:  39.6 KB

I just skimmed their thread I don't see a picture of the boot or mention of a resistor, just a spring.

Their plate is pretty.

-Rich
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      04-06-2021, 09:14 PM   #4
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Quote:
Originally Posted by rbryantaz View Post
I am using a rubber boot from another application.

The spring does have to be extended a bit and the end snipped off and formed into a smaller spiral to engage.

Here is a pic of the boot I am using. It is about 3-4mm shorter than the original but it covers the spark plug fine and has plenty of range on the spring.

Attachment 2572893

I just skimmed their thread I don't see a picture of the boot or mention of a resistor, just a spring.

Their plate is pretty.

-Rich
Idk if there is a picture of the boot, but they talk about it and might say what it came from. They also talk about the resistor somewhere in the thread, or might possibly be the other thread they made on there for coil testing where they talk about it.
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      04-06-2021, 09:26 PM   #5
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Quote:
Originally Posted by IllSic_Design View Post
Idk if there is a picture of the boot, but they talk about it and might say what it came from. They also talk about the resistor somewhere in the thread, or might possibly be the other thread they made on there for coil testing where they talk about it.
I am referring to a resistor between the coil and the spark plug. The B58 coil has a 1k Ohm resistance.

Here is a teardown of the boot with its internal resistor. It blurred a little but you get the idea...

Name:  b58 coil disection.jpg
Views: 4576
Size:  53.7 KB

I trimmed the resistor on the top one to see how if it would fit in the rubber boot (it will so I could put it in the middle of the boot if desired).

I could just trim the long spring down and thread the B58 springs into it where it connects to the resistor.

Overall I think it is likely not needed so I am going to test without for now.

-Rich
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Last edited by rbryantaz; 04-20-2021 at 01:40 AM..
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      04-06-2021, 09:42 PM   #6
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Hell yes! I was just trying to do research on this a few weeks ago. Super interested in running the b58 coils if possible
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      04-06-2021, 10:02 PM   #7
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Quote:
Originally Posted by ky0u View Post
Hell yes! I was just trying to do research on this a few weeks ago. Super interested in running the b58 coils if possible
Something simple should be all that we really need for this conversion.

Doing a 2D flat cut design with bolt on standoffs is much easier and cheaper than CNCing a large plate.
I could also remove the bolt that comes with the coil and use a longer bolt with unthreaded spacer and tap the plate for M6 but that also takes time and isn't really any better.

I started producing waterjetted COP adapter plates for the SRT4 Neon many years ago.

I have been meaning to do it for the n54 for a while.


-Rich
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      04-19-2021, 02:28 AM   #8
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B58 coil conversion up and running

I have it up and running.

It idles smoothly with no codes. I still have my under belly panels off after the e85 conversion so I didn't take it out for any pulls yet.

Here are the plates all installed:
Name:  b58 coils installed and wired.jpg
Views: 5123
Size:  174.5 KB

Crimping the little terminals onto the stock wires and getting them into the connectors was a bit of a pain (especially for cyl #6). I also soldered them just to be sure.

I have done a lot of soldering and crimping and still found these to be a challenge.
If doing it again I would cut off the stock wire with 3-4 inches back from the connector and then would use a shrink solder or crimp connector to splice in the newer style pigtail.

The stock #1 cylinder coil wires are just barely long enough so having the pigtail also makes that easier.

I am looking into some pigtails so that the wires are already crimped with the right colors to make that as clean as possible.

The engine cover fits over them just fine (the foam compressed a little but didn't have to be trimmed or removed):
Name:  engine cover over b58 coils.jpg
Views: 4781
Size:  140.9 KB


-Rich
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Last edited by rbryantaz; 04-19-2021 at 02:35 AM..
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      04-19-2021, 07:43 AM   #9
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Nice work!
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      04-19-2021, 09:25 AM   #10
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I think this design is cleaner than the other one. I would be interested in this whenever you start producing them.
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      04-19-2021, 07:05 PM   #11
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Beautiful! I want a set!
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      04-20-2021, 02:18 AM   #12
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Thanks guys,

It has been a fun project.

I can make more if people are interested...

I have a source for the boots and can get the plates cut with a week or so turnaround. If people don't need or care about having them them powdercoated that can keep the cost and turnaround time down.

The biggest thing that we would have to wait on are the connector pigtails. I did order some custom samples for myself which was a min order of 24 that I was considering instead of the direct solder/crimp on that should be here in a week or two. So I should have enough to supply 4 kits.

If I started these at an intro price of $180 (for the first 4) as for a kit without coils but with:

Plates plus hardware (self tapping hold down screw, hex threaded spacer plus attachment screw)
Boots/springs
Pigtails plus solder shrink connectors

Who would be interested, I see:

pysical
feuer
ky0u

Any others?

Thanks,

Rich
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      04-20-2021, 11:20 AM   #13
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Interested but my valve cover is VTT billet one, so I do not know how or where do I will hold the plate to?
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      04-20-2021, 12:16 PM   #14
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Quote:
Originally Posted by JMVela View Post
Interested but my valve cover is VTT billet one, so I do not know how or where do I will hold the plate to?
This design will only work with the stock valve cover.

Perhaps someday I could look at it but I think it is more likely to do an n55 version first.

Thanks for your interest though!

-Rich
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      04-20-2021, 03:49 PM   #15
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you can sign me up!

Nice...
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      04-20-2021, 06:19 PM   #16
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In @ $180
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      04-20-2021, 09:06 PM   #17
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Add me to the list.
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      04-21-2021, 03:44 PM   #18
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Thanks again for all of the interest!


I should have the boots tomorrow.

The 2 extra sets of prototype plates are ready from powdercoat today but I might not be able to pick them up until tomorrow. I made a second set in 1/4" thick and one in 1/8". The 1/8" is thick enough but needs a few washers to make the standoff to adjust the height and doesn't fully cover the boot (which doesn't matter). I will post some pictures when I get them back.

The threaded standoffs will probably change to round stainless steel rather than the aluminum hex pieces. I found a cheaper source for them in SS and I think it may look better than the hex pieces anyway.

It looks like these might be something that I offer even after the initial 4 are gone. It will probably be at a slightly higher price but I think I can still make them affordable! One the initial few are gone I will probably put up a classifieds thread.



I will work on setting up a little webpage similar to my e70 cargo support page for ordering for those that have already requested to be on the prototype list.

I think we are booked up for the initial prototype sales as long as everyone is ready to pay for them.

I am waiting on the the connectors, I will contact the supplier for a tracking number now.

-Rich
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      04-21-2021, 05:02 PM   #19
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Ready to pay whenever! Just shoot me a PM. Can't wait.
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      04-21-2021, 05:33 PM   #20
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Yup, can pay as soon as link or whatever is setup
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      04-22-2021, 02:27 AM   #21
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Is this plug and play? no coding or changes to MHD settings?
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      04-22-2021, 09:39 AM   #22
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R8's for the win!
Careful with them. They caught fire and burned my car. I have been rebuilding it but it was bad enough for insurance to total it. I have seen others report these have caught fire as well.
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