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gaijin

1M Clone Build

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I havent really put much up about this car to date, probably start something here.

Build List

2008 135i N54 6spd manual Jap import

Standard N54 3.0 6 cyl twin TD03 turbo engine and 6spd manual, replaced upgraded BMW 550i pressure & clutch plate, stock dualmass flywheel, hard gbox mounts and braces.

E92 m3 rear end swapped, subframe, LSD, all suspension arms & links, hubs, m3 front arms/uprights/hubs etc. Hard bushes installed for subframe and a few rear arms. 

1m genuine panels all round, replaced via factory BMW repair methodologies

AP Radi-cal brake kit all round, 6 piston front 380mm, 4 piston rear 390mm, SS braided lines. Full floating rotors on aluminium hats.

KW v3 coilovers, bump & rebound set up, front vorshlag top camber/castor plates set up 2deg neg camber. 

H&R sways front/rear, adjustable end links set up for lowering

245/35/19, 275/30/19 Hankooks to shred for now. 295/30/19's Continental's ordered for rear, 245/35/19 Michelin PSS Cup 2's for front arriving mid June '17. 

Rob Beck Next Gen turbos, Billet 15T Compressor wheel/RB Bullet nut, TD04 Thrust upgrade, High flow TD04L 11-blade high aero turbine wheel/RB high heat shield, and RB high flow oil drains.

Custom turbo outlet pipe, modified SS section. See photo 1.

RB silicon turbo intakes, stock filter placements, big filters from Burger Motorsport

VRSF 7" thick Intercooler, RB turbo inlet with HKS SSQV blow off valve. Ordered "Colossus" Intercooler to replace 7" VRSF.

Now running full methanol integration via JB4 ISO with CM10 nozzle, 60% meth/40% H20. Running 65 additive on JB4, adding meth at 6lb/in2, or 0.4bar onwards once oil is at 70deg C or higher.

Cant stress how good the meth kit works, Any flow restrictions, knock detected or avg ign retard the boost gets brought back by the JB4. Previous to the meth kit going in, the IAT, intake air temps, got really high, in traffic would see close to 50deg C. Took a long time on the M'way to get it back down to mid 30's, which would see the ECU pull timing and boost aggression in the mid range.

Now with the meth, each time you floor it, you can watch the IATs drop pretty quick, much better repeatability of power. Means you can spin the wheels over 120. Ive tested the car up to 27lb/in2, 1.9Bar boost, but have settled to 25lb/in2 circa 1.7bar. With this it'll slowly pull in front of new GSXR750's from standstill and easily from 180+ on closed roads. I put into the main fuel tank a blend of about 60% mobil 98RON and 40% E85 from the Gull Forest Hill. I get 300kms from the tank as a daily driver. The JB4 ISO is set up as a piggy back to the factory ECU to control methanol and boost and the full data logging which provides a live bluetooth connection, so the phone is a mini dash too. The ECU is reflashed via MHD tuning (free to DL, then pay for each map). I run the hybrid turbo E85 map or the race flash depending on the percentage of E85 is in the tank. Im limited currently on two fronts in regards to the power output of the car. The turbos are at the limit of airflow efficiency, and secondly the High pressure fuel pump and injector flow capacity. The meth spray is adding fuel which Im using to maintain AF ratios. This used to be considered 'unsafe' as there were little/no warning or safety devices that would protect the engine if there was a failure in the meth delivery. With the JB4 safety systems Im happy to move into meth as a fuel delivery device as well as cooling.  I limit boost through 1st and second, 10lb then 17lb then 3rd gear gets the full 25lb onwards. Also, for shits and giggles, it has a 2 step installed, so conveniently I can build boost from a standstill, I can get to about 8lb. With flames out the back of course. Installed is a no lift shift, so just bang the clutch and change gear while holding the throttle down maintaining close to the boost you've just shifted from. I have installed anti-lag but havent set this part up yet. If I've 2 stepped anyone I'm sorry, kinda like a machine gun going off in your face. More so now the custom mild steel rear exhaust has been replaced with a stainless steel one. 

Had the car in for its cert finally at Fraser Cars Birkenhead via Scott. Mostly required lock washers on parts of the car that BMW didn't think needed lock washers. Annoying, but them the rules. Otherwise the information is with NZTA to approve and get the plate on. Early June, says NZTA are happy bar a bump steer test booked in for mid June. Will be fine as virtually stock 1M front end and offset wheels are used with spacers.

The next plan is to install the Precision Raceworks Stage 4 low pressure fuel system (running three intank Walbro E85 pumps), independent & larger low pressure fuel supply/return lines, 6 x 750cc bosch injectors and port injection manifold spacer. This will allow a full E85 even E100 fuel in the main tank and likely the deactivation and sale of the meth system. Simply not needed with higher E85 content, if available. An ethanol sensor (Continental) will be installed in the fuel supply line which also gets integrated into the JB4 for complete fuel integration from E0 to E100. This should net about another 20-30kws without another turbo upgrade.......this fuel kit is due early July.....turbo's hmmmmmm....

Lastly, there are some MMP Stage 3 full TD04HL turbo's that Im eyeing up, which have seen 550 rear wheel kw's on full E85. Pushed, these are the limit of the stock N54 engine apparently, circa 900 crank hp. Incredible that its an open aluminium block with this level of strength. Who says 2JZ's are the strongest? Factory forged crank and miele pistons. N55 are definitely weaker engines. Not saying they are weak ok, just 'not as strong as N54's'.

However, I cannot stress the amount of misery there is in changing the turbos out, the main reason Im potentially unlikely to do so again. Took close to a week to change out over weekends and nights in the rain, fuggin misery.

E82 LCI Blackline taillights added late May '17 and LED bulb change out inside and at all exterior corners. Error free my arse!

So its taken me about 2 years to build it in my driveway, bar the panel and paint. Its cost a fair bit less than a real 1M, minus all the mods. Im guessing currently 410-430kws at the rears going from similar/same tune N54's in Aus. It sort of drives like a combination of a lazy boy and a fast motorbike. 

 

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Edited by gaijin
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Sounds like an absolute blast.  At least if you nod off to sleep in your lay-z-boy you're unlikely to wake up and find yourself passing vehicles at over the ton.  😉

Whats the first image of - I understand they're exhaust parts - more detail please?

 

 

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The first photo is the rear turbo outlet pipe. In RHD this pipe has to clear the engine and steering shaft. THey crush the tube in 3 sections all around the same place, terrible flow reduction. I ground the sections out and plated in SS then ground smooth. So this pipe flows hot pre-intercooled compressed air. I then wrapped it in heat shield wrapping stuff.

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do you know the overall weight of this vehicle.

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My estimate is around standard minus a few tens of kgs, say 1475 kg.  A bit of a porker still.

Apart from getting rid of 'bits' that are not deemed necessary, carbon boot and the mods done, some of which may add a little weight, some further work is to come,

Have some further weight reducers approaching, titanium wheel stud & nut conversion  (2 weeks time) and a lithium battery, should drop about 25kg

https://ozmoengineering.com/product/bmw-m12x1-5-studlugnut-kit/

Battery brand tba

Maybe seats in the future, but havent found something streetable that fits me, 6"3 and 105kg. A bit of a porker still.

 

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Talking of porkers, perhaps the 1M needs to go more J Lo?>

Some steel over-fenders that I had made up recently, fronts also.

RIP Kirsty Webb, thanks for the memories and mud on the car xxoo

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Edited by gaijin
Added memorial to friend
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After a twice round Nth Island in a month with the car, it performed perfectly. Amazingly. Great to get on the open roads and mix it up with the locals and other fast Euro cars, new RS6's, new M4s and give them a taste of the 1M. While moving away from E85 stations, I tried octane boosters in the fuel tank. While it worked for the engine, it was bad on my health, the stench and irritation with fumes coming back into the car with windows down was surprisingly bad. Anyways, car cleaned, LED lights installed into the cabin, external LEDs installed and coded and  Blackline tail lights installed. The rear 275's wear showing minimal tread depth, time to try something a more chunky. Enter 295/30/19 Conti Sport Contacts. 2.3% less circumference, meaning it'll be like changing the diff ratio from the 3.15 it is now to a 3.22. The tire fits, but its getting tight. Could potentially do a 305. Its on a 10" wide rear rim, so fits the rim better than the 275 did for sure. The extra width should help with grip.20170617_152825.thumb.jpg.b5da4f4cd2d171aa96dc021911b5f238.jpg

Still waiting impatiently for some other parts to turn up for the fuelling upgrades, but not a show stopper for now.

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Just bought this.

http://www.e90post.com/forums/showthread.php?t=1391643

sh*t just got exciting!

Ill push the clone over to Dan Slater @ Slater Fabrication for the manifold, he does great work, when you can ever book some time in...

Thread from where the kit has come from;

http://www.e90post.com/forums/showthread.php?t=1291848

Edited by gaijin
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well then ... this wont be sh*t

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Had a catch up Dan this avo after leaving work early, he's happy to receive the car this time next month to fab the manifold and exhaust. Better start collecting all the other bits....

 Photo of Phils 335i from Melbourne, who is packing the parts as we speak.

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Edited by gaijin
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Good luck with the build will be amazing. From of the reviews ive seen of the singles they can be problematic from a tuning perspective and dont suit a daily car. Hope it all goes well for you.

Going to sell the RB twins and inlets? :) 

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Something to do while it rains, install a titanium wheel stud kit. Fronts have some decent thread clearance, i.e. could have made them 5mm shorter, but rears are bang on. Look preeeety

 

Before20170701_134916.thumb.jpg.dcbdee676df98c89e80b9a43fd8568dd.jpg

 

After

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and better news, the turbo/intake manifold/intercooler is in the country, likewise stage 4 fuel system finally on its way from Oregon thanks to YouShop. Bought pretty much all the other parts from ST conversion, coolant and oil fittings, short nose air filter, boost solenoid from BMS. Specs on turbo is 67mm - 65mm turbo using a newer GTX3584R comp. wheel, dual ceramic BB Garrett core. Unsure on ex. AR ratio as yet. Made 570hp @ wheels on a lowly 17lb on the N54. Ill be pushing much higher than that. Android already loaded with E85 ST map, its keener than I am!

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On ‎23‎/‎06‎/‎2017 at 0:59 AM, jin108 said:

Good luck with the build will be amazing. From of the reviews ive seen of the singles they can be problematic from a tuning perspective and dont suit a daily car. Hope it all goes well for you.

Going to sell the RB twins and inlets? :) 

Yeah a fair amount of bits to sell, someone has there hand up for CP/BOV/7" Intercooler already

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threw in a revised oil cooler valve to increase oil flow to the stock oil cooler, along with new covers

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Scott at Fraser Cars finally placed the certificate by LVVTA defined as 'heavily modified/scratch built car' on Monday. Only taken about 4 months. Ended up doing a bump steer test, but no drama's there. Plate ran out of space so the additional info is on the paperwork.

No room in the engine bay so its loudly placed on drivers B pillar.

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The two step installed is eating pre cat oxygen sensors. Not really surprised. May look to remove this function. There is little need for 2 step from standstill for a daily, but its sure fun in the new Waterview tunnel. Ala sort of this vid below apart from louder. But at speed its quicker to get the shotgun/flame boom part. Especially with hardly much mufflering in the exhaust.

 

New progress with some non performance items, managed by some grace of the BMW God to find & buy these, OEM DTM E92 M3 GTR mirrors direct from BMW Motorsport in Germany (the CF housings and mirror glass). They are not bolt on's to an E82, but I have 3D printing in ABS at the ready and my old stock 135i mirrors to scan and model from. This will form the part that joins the CF mirror housing to the door, the triangle piece. They are circa 2012 items. IND makes them for a E92 but wants spastic money. Rather do it Kiwi and make me own ala the first photo from RKP composites. These arrive in a fortnight from .de

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Daniel from Brisbane has updated his RHD ST exhaust manifold. I'm not 100% on the design of this (due to heavy space restrictions), but I really like the CNC'd flange for sure.

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Also he can provide a slim Jim version of the stock steering column shaft that is so chunky and limits downpipe size likewise wastegate pipe screamer/plumb in room. Noting that the stocker is fat for a reason, by providing a crumple zone at its lower part in the event of a crash. Saves the legs n all.....I'm still keen to get hold of this over a local custom fab'd one which should save R&D time and both are being fabricated by Daniel for the NZ clone.

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In the mean time I wait patiently as usual this time for a new O2 sensor to turn up so the car wont splutter around at 7lb boost. Should be in this weekend and back to full skidz strength.

Edited by gaijin
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Machine Gun!!

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wow.  just wow.

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What kind of hp are you getting?

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Yesterdays guess would be 410rwkw, = 530 whp = circa 600+ hp. At the current turbos limits.

Today zero hp as the car is in bits.

All the fuelling kit and turbos bits arrived.

Removed VRSF 7" thick IC. Compared to the new joined core IC mothership, its mighty heavy. Purists look away, the butcher was in operation today getting this sucker in!

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Also the 2JZ ricer style intake manifold and port injection went in. This fit well actually pretty surprised. I'm attempting to get the new IC completed, with the intake manifold, while keeping the RB's and inlets in for now. Then set up the port injection and fuel kit and E85, then finally strap the GTW37 on. Car should be back running tomorrow.

 

BEFORE

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AFTER

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Edited by gaijin
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Good progress Friday but shite Saturday. 

Managed to wing a weekend off from the Fam Dams so I can play with the car.

After convincing myself that I should definitely NOT to upgrade most of the fuel system in one go, I woke and did just that. SO removed the Stage 2 fuel kit/pump a Walbro 450G/hr, I put together a Stage 4 system of 3 x Walbro 450G/hr and meaty electrical system. Almost there.

 

BEFORE = Stage 2 - 1 x 450G/hr

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AFTER = Stage 4 - 3 x 450G/hr

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With the intake manifold change, there are some wires to extend, my friend Lars will do this tomorrow or else he can stop drinking my beers.

 

Dummy slapped the turbo into position

Hmm, heaps of sh*t to sort out

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Edited by gaijin
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mirror time. Baby approves.

chopped up the old stock E82 ready for 3D scanning

Motorsport mirrors, both weighed 147grams each. Stock mirror is 1200g each.

Left glass fits nicely, right side is very motorsport, needs some glass sanded back to fit nicely.

Damn rain, stopping play outside.597298884b49a_mirror2.thumb.jpg.c22b2d19ec39a4949e359773a22715d7.jpg59729889b9981_mirror3.thumb.jpg.ddca0b2abd5ab3c1f95a39e93c0c3c32.jpg5972988b1e6be_mirror4.thumb.jpg.7f78428ee5bacd47b822fbf4bf8f3eee.jpg5972988c90616_mirror5.thumb.jpg.fa836976f2df0f3dc47bde5ab364ef16.jpg5972988e05055_mirror1.thumb.jpg.8d30782c1189c39224d8617e33e6d18d.jpg

Edited by gaijin
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