Early birds, early pictures. N54 rebuilt

[csl335i]

Let me introduce myself. My name is Laszlo and I am located at Budapest/Hungary/Europe. I am a proud owner of different BMWs, such e93 M3, F10 M5, F20 125d, e92 335i. At this moment i would like to introduce some early
pictures about my e92 335i DCT rebuilt, which has started almost a year ago. And we still need some time to finish, hopefully by the end of this year.

I have already opened a new thread on the other forum, but would like to open here as well.


Regarding my e92 335i, all rebuilt has begin, when i was on a business trip with my 335i and my secondary oil cooler line has wear and blown up.
I have lost 4.5 liter (!!!) oil from 6.5Liter. Oil line was replace, engine was refilled with oil and however i cannot hear any damage or strange noise, i decided to tear down the engine, check everything and completly rebuilt. NOt just the engine, of course. During my project, the following topics were involved. I have tons of pictures, some topics are finished or almost finished, some needs to be finalized.
All of the modification is done in-house by my tech-friends.


My car is/will be street driven, sometimes, spirited, sometimes hard.


THIS PROJECT IS NOT ABOUT HUGE HPs, BUT ABOUT THE PATH WHICH I AM WALKING ON AND RESULTS SOME INCREDIBLE MOMENTS AND TECHNICAL INNOVATIONS.


Interior.
Custom leather upholstery, Recaro Sportster CS seats with seat heating,
additional display for engine datas, Turbo RPM display x 2, EGT display


Full M3 suspension conversation.
Front: LEFT and RIGHT tension strut WITH RUBBER MOUNTING, LEFT and RIGHT wishbones, LEFT RIDE HEIGHT SENSOR BRACKET, REGULATING RODs, M3 Bilstein B6 coilovers, M3 FRONT coil springs, LEFT and RIGHT wheel carrier,
Guide support and spring pad. H&R sway-bar.


REAR: REAR AXLE CARRIER, LEFT and RIGHT RUBBER MOUNTINGs, LEFT and RIGHT wheel carrier, Rubber mountings, LEFT and RIGHT camber links, LEFT and RIGHT wishbone, Steering arm with ball joint, M3 Bilstein coilovers, M3 springs. H&R sway-bar.


Custom made Brembo brake systems.
Front: 8-pot Brembo, Two-piece floating brake disc. 380x34mm
Rear: 6-pot Brembo, Two-piece floating brake disc. 355x30mm


Properly sized and modifed F10 M5 master brake cylinder which replaces the factory one to have normal brake pedal feel and brake force for the front and rear brakes. This was custom made to my brake system.


Hand-brake is replaced by hydraulic cylinders, which actuates the rear brembo brakes.


Differential, half-shafts.
335i differential house with custom fitted e34 M5 differential internal.
Custom fitted 2.56 final gear (i have DualClucthTranny)
Custom fitted e92 M3 drive flanges.
Custom made transmission/differential cover.
LEFT and RIGHT e92 M3 output/half-shafts.
Motul 75W140 differential oil.


Custom made exhaust systems.
Ceramic coated downpipes.
Ceramic coated mid-section with HJS sport cats, etc.
We finished the end-section and will continue the exhaust system,
once we are ready with the exhaust manifolds and downipes.


Engine rebuilt.
JE forged pistons with ceramic coating.
Carillo forged rods.
Nitrited crankshaft and crankcases.
ReBored and rehoned cylinders.
Chocked cylinders.
Ported cylinder heads. Ceramic coated ports.
Ceramic coated cylinder heads and valves.
Slightly modified valves.
Okada plasma coils. Okada Plasma Ground.
NGK spark plag
Relocated coolant reservior.
Relocated water pump.
Custom made alu intercooler
Custom made full alu watercooler radiator
Custom fitted SETRAB oil cooler.
850W FAN with relays.
Custom made charge pipes, water lines and oil lines.
Custom made air intake system with K&N filter.
Modified BMS OCC.
Forge DV.
JB4 G5 and flash.
Motul 300W Power 5W40 motor oil.




Exhaust manifolds and turbos.
Custom made exhaust manifolds (will be ceramic coated)
Custom made two single-scroll hybrid turbos with BALL-BEARING CHRAs.
Turbine houses will be ceramic coated as well.
Turbos have "Twin-scroll" effect, which means:
- Both of the turbos have the same turbine and compressor wheels
- Both of the turbos have the same Compressor house.
- One of the turbo has larger turbine house, while the other has smaller turbine house (compared to each other).
- The larger turbine house has smaller wastegate, while the smaller turbine house has larger wastgate (compared to each other).
- Wastgates will be controlled by Forge actuators operated by vacuum. There is also a plan to exchange the vacuum actuators with pressure based actuators.
Theoretically, this two single-turbo all-together can produce maximum 530-550HP, not more, which is more than enough for me.


Full M3 body conversation
We have all of the parts, this will be the last part of the project.
After fittment, respraying will be done.


Wheels
Breyton 19inch or OEM BBS 19inch, not decided yet.
Continental SportContact P5 tyres (same as on M3)


DualClucthTranny
Big question is, that should i upgrade them or not. My F10 M5 has the same clucth-plates as e92 335i, so maybe the clucthes are not the weakest points.
I also purchased the 16 clutch-pack SSP clutch, but i dont want to install them until further experiences based on other forum members.

Fuel-System upgarde
Big question also, that should i upgrade them if i will have no more 500HP?


I will post pictures as well regarding the topics soon.

Happy visiting! Laszlo

[csl335i]

Originally my car has baige interior. I choosed RECARO SPORTSTER CS seat custom made seat heating. Inside performance display will be fitted soon and will have 3 analog display: Turbo RPM rear, Turbo RPM front, EGT

[csl335i]

We install every bits of M3 supsension including the following:

Front: LEFT and RIGHT tension strut WITH RUBBER MOUNTING, LEFT and RIGHT wishbones, LEFT RIDE HEIGHT SENSOR BRACKET, REGULATING RODs, M3 Bilstein B6 coilovers, M3 FRONT coil springs, LEFT and RIGHT wheel carrier,
Guide support and spring pad. H&R sway-bar.


REAR: REAR AXLE CARRIER, LEFT and RIGHT RUBBER MOUNTINGs, LEFT and RIGHT wheel carrier, Rubber mountings, LEFT and RIGHT camber links, LEFT and RIGHT wishbone, Steering arm with ball joint, M3 Bilstein coilovers, M3 springs. H&R sway-bar.

[ncat10]

Nice man! About Full M3 body conversation. I also did the reincarnation of the m3 body , if you need help, please contact!

[csl335i]

We have some Brembo stuff in the garage, so I choosed not to order BBK, but install what we have.

Front: 380x34mm two peace brake discs (D2 Raceing discs). Brake hat was custom made by us. 8-pot Brembo brake caliper (I think they came from an RS5).

Rear: 355x30mm two peace brake discs (Brembo discs). Brake hat was custom made by us. 6-pot Brembo brake caliper.

Master brake cylinder: to improve the brake pedal fee based on my 8 and 6 pot huge Brembo brake calipers, we decided to measure the factory brakes/fatcory master brake cylinder and upgraded brakes. We made some calculation how we should increase the capacity of the master brake cylinder
to have the same pedal fee, while have the same brake force % for the front and rear (based on my custom setup).
Conclusion: F10 M5 master brake cylinder has the same capacity, what we needed, so we took one and slightly modified it to fit the 335i environment.

[csl335i]

As we have the full M3 suspension on my car, i decided to have M3 half-shafts as well. We decided to keep the 335i diff house, but have LSD in it, which is compatible with M3 half-shafts.

We renewed and custom fitted an e34 M5 diff internal with my final gear 2.56 (I have dualclucthtranny) and then custom fitted the M3 drive flanges (cannot see on the attached pictures yet, but will post pictures). We already fitted the M3 half shafts without any modification (cannot see on the attached pictures yet, but will post pictures).

Custom made differential cover is on the way, once we ready with it, i will post a picture as well.

[csl335i]

Not much pictures at this time. We have finished the end section and planned what we have in the mid-section. I put two HJS 200 cell sport cats at the begining of the mid-section.

As we did in the past, we apply ceramic coating on the downpipes (externally, internally), mid-section, end-section.

[csl335i]

Maybe the most interesting part. My engine has 68k km in the clock, so after tear the engine down, we clean everything properly. Some part of the engine was surface treated with glass-pearl blusting (which is more or less the same technology like sand blusting, but more refined).

See pictures after glass-pearl blusting.

[csl335i]

We rebored and rehoned the cylinders and choped them.
We have JE forged pistons and Carillo forged rods.
We ported the cylinder head intake and exhaust ports and slightly modified the valves as well.
I have Okada coils and Okada Plasma Ground.
We nitrated the camshafts and crankshafts. The goal was to strenghten the surface and decrease the resistant of the surface. This was special nitrating in salt technology. When you pull your finger on the dry, but nitrated surface on the camshafts you have a feel, like you put tons of oil on the camshafts.

We use in-house developed ceramic coating on different part of the engine:

- cylinder head and valves: ceramic coating with nano gold layer
- top of the pistons:ceramic coating with nano gold layer
- cylinder head exhaust ports: ceramic coating with nano gold layer
We make a heat trap/heat mirror (bottom: piston head, top: cylinder head and valves).

Ceramic coating can decrease the engine heat by maxmimum 30%, while keep all the necessary heat in the combustion chamber, which results more efficeint fuel burn. After burning, the exhaust gas escapes through the internally ceramic coated exhaust port and therefore the kinematic energy of the exhaust gas is not wasted to overheat the exhaust port, but instead it speed up. VE is also increased, emission is slightly decreased.
Exhaust manifolds and turbine house will be ceramic coated as well to keep the system in one.

[Flinchy]

awesome stuff!

why not just go the full E9x M3 diff with custom final drive?

would fit easier, and probably end up a LOT cheaper

EDIT: and those block guard things, how do they help anything at all?

and wow those ports remove a LOT of material haha

[csl335i]

awesome stuff!

EDIT: and those block guard things, how do they help anything at all?

and wow those ports remove a LOT of material haha

Those block guards chops the cylinders againts the engine wall. When you have high torque, the pistons pushes the cylinder walls with so much force, that maybe the top of the cylinders start slightly move.

[csl335i]

Custom made full alu water cool radiator is on its way. Still need some modification and connections.

We also custom made a two-line intercooler.

850W Performance fan will be fitted. Coolant resorvier and water pump will be relocated and the LEFT side engine suspension will be modified (because of the turbos downipes and exhaust manifolds.)

[UsualSuspect]

Amazing work so far! The leather looks incredible!

[csl335i]

We designed two-single scroll turbo, but with different AR turbine housing.
Ball-bearing CHRAs.
Compared to each other, one turbine house is larger, one is smaller.
The smaller turbine house has larger wastgate and the larger turbine house has smaller wastgate. And will have almost identical backpressure after the turbine side. We call it "Twin-scroll effect".

Our exhaust manifold and turbine house will be ceramic coated as well.

Wastgates at this moment will be controlled by Forge actuators, which will be operated by vacuum, however, we have a plan later to try boost operated actuators as well.

Turbos will have Turbo RPM sensors as well.

We have to design the location of the cooler pipes/charge pipes and suction pipes very carefully and definitly we will use some ceramic coating and bandage as well on different pipes to prevent overheat from the downpipes and turbine house.

[Doyle]

Would you mind posting or PM'ing the measurements of the stock brake system? Master cylinder, F/R piston, etc.

Thanks, and amazing work. Glad the platform is finally being advanced to this level.

[Payam@BMS]

Now this is a build. Not even, this is a project holy crap. Talk about customizing and just building a new car. Absolutely badass.

[ra2289]

Very nicely done.

[V8Bait]

Dat interior. Excellent work! I'd recommend upgrading the oil cooling system while you're at it.

[csl335i]

Dat interior. Excellent work! I'd recommend upgrading the oil cooling system while you're at it.

We plan to have one Setrab front mount oilcooler. No additional cooler, no factory cooler,
just one front mount cooler.
I am using Motul 300V Power 5W40 oil, which is a very good oil.
I am not afraid of high oil tempretaure, as we significantly reduce the engine heat by our ceramic coating system, which, by the end results oil temp no more than 115-120celsius, which on the other side is also essential to improve the efficency of air/fuel burn.

There is a good reason, why bmw keep the oil temperature a little bit high, than as usual in this DI engine.

[Sticky]

Great thread! Post #9 and #14 especially...

[rader1]

Holy crap... This is nuts.

[Legionofboom]

The seats are brilliant.

Please post more info when you can.

-All BMW drivers everywhere

[Flinchy]

Those block guards chops the cylinders againts the engine wall. When you have high torque, the pistons pushes the cylinder walls with so much force, that maybe the top of the cylinders start slightly move.

yeah i understand what a block guard does

but what do THOSE block guards do? they sit at the top, seemingly not welded in, or bracing further down?

i'm just confused as to how this exact design does anything?


ED: those turbos though

that looks awesome!.. still a little small, but really really really cool!

why not keep the factory vac actuated wastegate setup? the DME would be happier, and it's been proven to work nice and bolt-on by vargas?

that intercooler + oil cooler looks pretty freakin awesome too!
those brakes are ridiculous

and

yep, this has been incredibly inspirational for me tbh. amazing stuff

gotta step my game up now

[bobS]

Great build, glad you posted these here...... i'll be anxious to see this car running!

[marv85]

Wow. where did this come from?!

awesome work. please keep posting pictures.

Im also interested in your boost control scheme (if you have one already)