N54 Rebirth - Forged Internal Build

[The Ghost]

I've building building my N54 over the last few months and wanted to share my progress.

Setup:

• N54, FBO, 6MT (Spec 3+)
• VM single turbo kit, PTE 6466 G2
• JB4 G5, back-end flash (MHD)
• BMS/CPE Port Injection kit
• JB4 controlled Split Second injector controller
• Fuel-it Stage 3 dual LPFPs
• Fuel-it FPR, -6AN feed/return lines
• e85

Engine:

• JE pistons (1 overbore, standard compression)
• CP/Carillo rods
• All else stock

Build and dyno can be see here:

http://tinyurl.com/gs6anp7
https://www.instagram.com/the_ghost_bmw/

Special thanks to Livnpaintball2 who pioneered the [openly-shared] DIY N54 build and shared his build secrets to help make this happen.

I have a ton of data on both the build (parts weight, methodology, issues) as well as logs that I'll post when I have time. I was pleased with the results, especially considering it was 100 F in the dyno bay.

Log of highest pull:
http://datazap.me/u/ghost/dyno-33psi...24&tmax=100.00

Happy 4th!

[Payam@BMS]

830whp and 730wtq @33 psi and such a beautiful graph. This is amazing, and the log is so damn clean too. I honestly think this is the best ST graph/curve I have ever seen. So much power under the curve. Time for 4 bar map sensor and 40 psi. Lets see some 900whp runs . Oh btw time to change that signature

[Chris@VargasTurboTech]

Looks awesome! Nice work putting the package all together.

[Mikey]

lets see this get over 900whp.

[jt0407]

Did you use ARP head studs?

[xShadows]

When I think built engine I expect a closed deck usually. I thought it was because the high boost ovals the cylinder bores and it helped prevent that? I'd rather have stock rods and pistons WITH a closed deck rather than forged internals and open deck. I could just be crazy though.

[Ericbh77]

Excellent work Ghost! Looks real good.

[Stucks]

Cool build thread and nice numbers. I agree with Payam, that graph looks awesome.

[whathedunks]

Awesome build! I may have missed it, but what exhaust are you running?

[Alpine]

Agreed with Payam, that graph is epic!

Question, while I echo the concern for keeping open deck, I'm curious why you left the rod bearings stock given how many have had them give out recently.

[The Convert]

Agreed with Payam, that graph is epic!

Question, while I echo the concern for keeping open deck, I'm curious why you left the rod bearings stock given how many have had them give out recently.

Lots of people have had rod bearings go lately? I must have missed it. I recall one, maybe two, but with HIGH mileage, and this is a new motor now. So, doesn't seem applicable to me. Biggest thing I'd be concerned about would be the cylinders going out of round over time.

[Payam@BMS]

Biggest thing I'd be concerned about would be the cylinders going out of round over time.

I keep reading/hearing this over and over and I still to this day have never seen proof of it. Where is the blown motor with oval cylinders, what's there to hide that I'm not understanding.

[Velocity26]

According to the log, that was 36psi of boost

[The Ghost]

Thanks for all the positive feedback!

Did you use ARP head studs?

Stock head bolts. Everything is stock except the pistons and rods. All of the bearings are new.

Looks awesome! Nice work putting the package all together.

Thanks! You were a big help (check credits in vid :-p )

According to the log, that was 36psi of boost

Right, it spiked in the midrange, but settled to 33psi which is where it made peak power.

[The Convert]

I keep reading/hearing this over and over and I still to this day have never seen proof of it. Where is the blown motor with oval cylinders, what's there to hide that I'm not understanding.

Talk to Jake H at Motiv. I think he's the only one who has seen it so far, but he's also the only one with a true track car and was also dd'ing the car at over 800whp for a year plus.

[The Ghost]

With my setup there has been two issues:

1. Reported knock (false?)
2. Crankcase pressure

For the knock, even at 17psi (WG pressure), 6 degrees advance, and e85 there were lots of timing corrections. I decided to use BMS' solution (HERE), using potentiometers to allow adjustment of the knock sensitivity. The plan was to put it on the dyno and tune there. On the dyno I saw corrections once (2 degrees on two cylinders), when running 9.5 degrees of timing at 26psi. I reduced timing to 8 degrees peak and it didn't return. Similarly, I looked for signs of knock on the dyno but only saw it once. Upon closer inspection, that was a fueling blip which caused the anomaly. Attached is the graph with the dip (9.5 degrees) with the following graph being the same setup but with 1.5 degrees less timing. Also a picture of the POTs.

Regarding crankcase pressure, this is only a suspicion. My crankcase seal leaked underboost so I replaced it, but it blew-out within 100 miles. I'm running factory PCV setup with RB PCV and BMS OCC. I'm going to look into options to allow better venting of crankcase. I also added an NPT fitting to the oil cap so I can measure the pressure.

More to come (bedplate rig, component weight comparison, etc.).

[Alpine]

Lots of people have had rod bearings go lately? I must have missed it. I recall one, maybe two, but with HIGH mileage, and this is a new motor now. So, doesn't seem applicable to me. Biggest thing I'd be concerned about would be the cylinders going out of round over time.

gotcha. Makes perfect sense when you put it that way. Congrats on the build and the numbers!

[Milan]

GHOST out of curiousity what AFR are you seeing on the dyno?

[Payam@BMS]

Talk to Jake H at Motiv. I think he's the only one who has seen it so far, but he's also the only one with a true track car and was also dd'ing the car at over 800whp for a year plus.

That's all I hear all the time to be honest lol.

[CKI@Motiv]

Awesome graph! very nice power curve.

Thanks for the credit! looks like those VANOS do make a pretty big difference

[The Ghost]

GHOST out of curiousity what AFR are you seeing on the dyno?

The dyno-logged AFR is shown at the bottom of each graph. It more or less matched what the JB4 reported (slightly richer than JB4 on the top end).
For mobile devices Vimeo doesn't embed (video link: http://tinyurl.com/gs6anp7)

It looks like the fuel system is about done, as HPFP is falling at the top end and subsequently AFR starts to lean some. Looking forward to what the vendors have in the works.

[The Convert]

I also added an NPT fitting to the oil cap so I can measure the pressure.

That's what I like to hear! Drives me nuts when people talk about CC pressure, but don't take the time to correctly measure it. Let us know what you see.

[berns]

wow, what a $#@!ing curve. awesome work and a solid grouping of parts. I take back what I said about big ST setups on this motor. Makes me want to see what a 6062 would do even more!

[Ericbh77]

@ghost, do you by chance have the ports in your head plugged or not?

[The Ghost]

@ghost, do you by chance have the ports in your head plugged or not?

No, stock PCV setup, with RB PCV valve and BMS OCC venting to atmosphere.

Im looking at the RB external PCV system, but that doesn't seem to help during boost (it provides vacuum to crankcase during non-boost situations).