VTT 2+, Port Injection Build - Dyno Progress

[The Ghost]

Per my old thread I proved that the stock turbo inlets were restricting flow at higher boost levels and so I did some testing and built custom intakes. Since then, I installed BMS's (Burger Tuning) port injection kit, Fuel-it Stage 3, and ditched the meth using full E85.

Setup:

• N54, FBO, 6MT
• JB4 G5, Cobb backend flash (ATR)
• Custom 2.25" turbo inlets, w/BMS DCI
• BMS Port Injection kit
• Split Second injector controller (AIC1-G4H)
• Fuel-it Stage 3 dual LPFPs
• e85
• Stock exhaust (catted)

Specs on Intakes:

• 
  
  • Front intake specs: 2 1/8" 90 degree silicone elbow, 2.25" pipe directly into filter on passenger side. Piping covered with head reflective foil
  • Rear intake specs: 2 1/8" 90 degree silicone elbow, about 14" of 2.0" aluminum pipe, 45 degree 2.25" silicone coupler to about 14" of 2.25" aluminum piping, 45 degree silicone bend to filter (2.25"). The picture below shows the upper half the intake.
  • BMS DCI filters reused
  • Vac canisters moved to driver's side (shown in attached)
  • PCV retained, mounted bung near same place as stock (shown in attached)

The dyno photos in order are:

• My maxed FBO meth/e85 car vs. my final tune today
• Comparison of timing changes (4-7 degree ramp, vs 7-9 degree ramp)
• FBO map 0 baseline vs. today's final tune
• All plots from today (tuning iterations)

Here is a log of the last dyno run:
http://datazap.me/u/ghost/2015-02-05...&data=1-3-4-11

Misc notes:

• Targeted 12.7:1 AFR (max power lean e85), however PI map needs work as it goes very rich (10:1) on spool as well as at 6500rpms. I didn't have time to keep reflashing the AIC, so I'll do that at a later time which should help torque and top end.
• Adding a small amount of timing made a HUGE difference in power (especially top-end). I decided to stop where I was as I was happy with the progress.
• These turbos (with these intakes) can make any reasonable boost it seems. 26psi@7krpms has a 66% IDC.
• Next mod is probably exhaust. While the e92 exhaust is supposedly pretty free-flowing, at 600+whp, I suspect there are gains to be had going to a 3.5" single exhaust without cats.

Special thanks to Terry@BMS for the extensive support and parts, Fuel-it and VTT both for good components and support.

[The Ghost]

Here are some pictures I took over the weekend.

[Newb54]

Those intakes aren't the prettiest ones out there, but A+ for ingenuity and they give others a good idea for some diy's. Those are some pretty impressive numbers overall. How difficult was the PI install with the controller and everything?


Edit: just reread my post, wasn't trying to knock you down at all, the finished product after install looks great.

[Formula1rr]

Results look great. Thanks for posting! I wonder how much more is left in these...

[SCGT]

Nice work dude! Fantastic results! Congrats.

FYI I switched to the Corsa 3.5" single exhaust and made about 12ish more hp up top. That was at about 460-470 whp.

[klipseracer]

Great!

[Payam@BMS]

Wow!!! 640whp Full e85! Looks soo good man. Congrats on the build, you worked hard going back and forth. You deserve this brotha!

After looking at the log again Cyl 5 is taking massive timing loss. How are the other logs with Cyl 5?

[Steve@Fuel-It!]

Wow...nice job...congrats!

As you mentioned, your fuel system needs dialed in a bit. Your trims maxed out both positive at tip in and negative the rest of the time. While JB4 doesn't log below zero (0 = -20 on JB4), I'm guessing you hit negative 33 and this is most likely what started forcing you rich. You can see the FCV was freaking out and the DME started pulling PWM to the LPFP doing everything it could to lean it out to target.

Again...really nice work, I know you were busting your hump to get this done.

CONGRATULATIONS!

[Peter @ Pure/PTF]

Thats some great results!

[Njz]

Awesome stuff. Inlets and PI incoming asap.

[drfrink24]

After looking at the log again Cyl 5 is taking massive timing loss. How are the other logs with Cyl 5?

Why is it always cylinder 5 with the N54? I swear its becoming my obsession with this platform... do we need to start a paypal donation site so we can pool a sizable bribe to some BMW engineer with access to the right tables to in the DME?

[lulz_m3]

Why is it always cylinder 5 with the N54? I swear its becoming my obsession with this platform... do we need to start a paypal donation site so we can pool a sizable bribe to some BMW engineer with access to the right tables to in the DME?

Cylinder 5 is generally the first cylinder to let go. Might be able to fix this with a better intake manifold, but i highly doubt exposing additional tables would help in this situation.

[Stucks]

wow, awesome results ghost! 640whp must feel great! as for that cyl 5 drama.....like others have said it may have to do with the intake manifold "hump"

[jyamona]

Awesome results! Seems like you will easily take the stock frame record for yourself once you get that top end fueling leaned out! Just the AFR difference alone should get you there, plus there's probably another 1* of timing you could throw at it as well. Do it!

[Alexx]

Amazing results!

[Legionofboom]

Great results Ghost, The BMS system looks good

[135pats]

Outstanding results OP...Know you worked hard on the build to get it where it currently stands. Well done!

[Torgus]

Awesome results. The stock exhaust has to be a restriction at these levels. On top of gaining some power you will drop 40 lbs so a 3.5 is really a win win.

[Torgus]

VRSF is taking a while with their 3.5 The turner Corsa 3.5 is available now and clears the X brace.

3.5 exhaust and perfect tuning has got to be worth a decent pump in HP.

I would think with headwork you might even get close to 700whp which is just stupid from stock frames on a 3 liter.

[Terry@BMS]

Nice!

If you need helping dialing in the AIC maps let me know. It has nice logging feature you can use which lets you log boost, RPM, and DC, and their software doesn't interfere with the JB4 logging. So you log both then view, adjust the maps, and reflash. Spool up is a tricky area. You want enough that high pressure doesn't crash there. But not so much that trims get pushed beyond -33%, of course.

[DavidV]

Impressive. Congrats.
I really like to see what you end up with power wise once everything is dialed in.

[TT-Tom]

Well considering his log is pretty decent for running so rich, with the exhaust and dialing everything in I don't think 650-660 is out of the question on current boost levels. The wgdc is pretty low and im assuming bp is as well, doesn't seem to be at the limit yet! Awesome results!

[Tony@VargasTurboTech]

Not sure how I missed this thread! Awesome work man! Its great to see a customer running 100% E85 basically match out numbers with a work in progress tune! Love all the work you have done, and very impressed with getting it all done so quick. You have my email i you have any questions at all!

Edit: One thing I do see in the difference in the PI ,and Shotgun system is. With the Shotgun in place, there really is no set up. Install, and with a basic setting out of the box we have seen near perfect trims, and AFR's with no adjustments as the DME is still in charge of most of the fuel. Both systems work very well, the PI just takes a little more work to set up. Each has their pros and cons, a very nice benefit of the PI is clean valves!

[Njz]

Per my old thread, I proved that the stock turbo inlets were restricting flow at higher boost levels and so I did some testing and built custom intakes.

Since then, I installed BMS's port injection kit, Fuel-it stage 3, and ditched the meth using full e85.

Setup:

• N54, FBO, 6MT
• JB4 G5, Cobb backend flash (ATR)
• Custom 2.25" turbo inlets, w/BMS DCI
• BMS Port Injection kit
• Split Second injector controller (AIC1-G4H)
• Fuel-it Stage 3 dual LPFPs
• e85
• Stock exhaust (catted)

Specs on Intakes:


The dyno photos in order are:

• My maxed FBO meth/e85 car vs. my final tune today
• Comparison of timing changes (4-7 degree ramp, vs 7-9 degree ramp)
• FBO map 0 baseline vs. today's final tune
• All plots from today (tuning iterations)

Here is a log of the last dyno run:
http://datazap.me/u/ghost/2015-02-05...&data=1-3-4-11


Misc notes:

• Targeted 12.7:1 AFR (max power lean e85), however PI map needs work as it goes very rich (10:1) on spool as well as at 6500rpms. I didn't have time to keep reflashing the AIC, so I'll do that at a later time which should help torque and top end.
• Adding a small amount of timing made a HUGE difference in power (especially top-end). I decided to stop where I was as I was happy with the progress.
• These turbos (with these intakes) can make any reasonable boost it seems. 26psi@7krpms has a 66% IDC.
• Next mod is probably exhaust. While the e92 exhaust is supposedly pretty free-flowing, at 600+whp, I suspect there are gains to be had going to a 3.5" single exhaust without cats.

Special thanks to Terry@BMS for the extensive support and parts, Fuel-it and VTT both for good components and support.

Super jealous of this result, you have put in more work and time than I have been able to spare to get everything buttoned up and it is really showing in the results here. Must be a freaking blast to drive!

[CKI@Motiv]

looks good OP. Im a little concerned with the LP fuel regulation. Please tell me your on the stock FRP. With pressure swings like that its going to be near impossible to get PI injectors dialed in. I think @SteveAZ is working on fuel pressure regulation for the BMS kit but its defiantly in need of one.