gaijin 174 Report post Posted June 18, 2023 Promise this is the last fuel tank post. Finally got my head around what I wanted. Kind of a DIY Stage 4+ OEM EKP with cooling controlling 535, Remove OEM pressure reg and filter by cutting away, revealing a -6 or thereabouts nubbin to directly attach to from the check valve, fed from the 535. Outlet of check valve the only restriction, i.e. the smallest diameter, but this is only for 1-2cm. . This nubbin here, connects directly to the top hat externally, now fed from check valve and 535. -6 to -4 thereabout, the final restriction frontier! Ill leave it, check valves are needed to start the car quickly without draining all the fuel back into the tank Two separate fuel feeds up and out of the OEM now filter less and regulator less hat, removing every major restriction Feeding two separate -6 lines joining a -8 line with 10 micron on one line, -6 return to pump side hat. The two feed lines; One 450 pump triggered once some level of boost is reached, One spare in tank pump not connected. Replace all quick connect connectors, feed and return lines, note double O rings Pressure regulator to engine bay se to 70-75psi. So its a properly controlled returned system without much restrictions, easing the life of the EKP controlling the 535, all via PID to the LPFP with sensor up next to the HPFP as per OEM. Precision raceworks sell a drop in reg/filter hat but it'll be $1.5k or so. Far too much, this will do the same Tank goes back in today, cleaned SS fuel tank hangers and painted ally mounts Happy to have fuel tanks out of my life now, really happy. Quote Share this post Link to post Share on other sites
elias 263 Report post Posted June 18, 2023 Looking good! Where did you get the headlight lens from and what did you use to seal it back up? Quote Share this post Link to post Share on other sites
gaijin 174 Report post Posted June 18, 2023 (edited) Elias, I think Aliexpress for both. The sealant comes in a box curled up like licorice, so you just roll it out and shove it in, heat it for a while in the oven and push lens back in, repeat 2- times and its sweet. Getting the old hardened sealant out is the misery. Better to do this, some people use the old sealant or just lay over it, meh, rather try do it just once. Will get them ceramic coated to try and last as long as possible if the car ever sees the sun... Tefanball Factory Store 1Pcs Butyl Rubber Glue Headlight Sealant Retrofit Reseal Hid Headlamps Taillight Shield Glue Tapes Car Door Seal Accessories NZ$ 23.35x1 gouhuo Store For BMW 1 Series E81 E82 E87 E88 2004-2011 Headlight Shell Transparent Headlamp Cover Lens Plexiglass Replace Original Lampshade 2PCS left and right NZ$ 154.12x1 Edited June 18, 2023 by gaijin pic 1 Quote Share this post Link to post Share on other sites
Cement 892 Report post Posted June 18, 2023 I'm going to miss those those fuel tank posts 😂 Quote Share this post Link to post Share on other sites
gaijin 174 Report post Posted June 18, 2023 1 hour ago, Cement said: I'm going to miss those those fuel tank posts 😂 Like I've been in purgatory FML Quote Share this post Link to post Share on other sites
elias 263 Report post Posted June 19, 2023 22 hours ago, gaijin said: Elias, I think Aliexpress for both. The sealant comes in a box curled up like licorice, so you just roll it out and shove it in, heat it for a while in the oven and push lens back in, repeat 2- times and its sweet. Getting the old hardened sealant out is the misery. Better to do this, some people use the old sealant or just lay over it, meh, rather try do it just once. Will get them ceramic coated to try and last as long as possible if the car ever sees the sun... Tefanball Factory Store 1Pcs Butyl Rubber Glue Headlight Sealant Retrofit Reseal Hid Headlamps Taillight Shield Glue Tapes Car Door Seal Accessories NZ$ 23.35x1 gouhuo Store For BMW 1 Series E81 E82 E87 E88 2004-2011 Headlight Shell Transparent Headlamp Cover Lens Plexiglass Replace Original Lampshade 2PCS left and right NZ$ 154.12x1 Sweet as cheers for that, much appreciated! Quote Share this post Link to post Share on other sites
gaijin 174 Report post Posted June 20, 2023 EKP v2 cooler arrived and installed, its kinda plug n play, not pricey and a worthwhile mod with a larger pump Inside, no heatsinks, you can see its been getting hot, resin has browned a bit heatsinks mounted on New cover with fan back in its home Not a BMW photo but looking good as a family car tonight, now its cold itll be time to see/get the dragy times, the TCU tune feels really aggressive with solid larger turbo spool sounds. 0-100 still in 3.1 zone on a warm day on NZ roads, winter and wider front PS4S and semis on the back should/could improve a little, running 255/30/19 fronts with 235/35/19 rear, off square as per RS3 option. Slides around nicely now Spoke with Dan at Torque about Maxx ECU race purchase, Ill get the n54 adapter from pnpecu directly. Be gone BMW ECU, be gone! 1 Quote Share this post Link to post Share on other sites
Cement 892 Report post Posted June 20, 2023 3 hours ago, gaijin said: 0-100 still in 3.1 zone on a warm day on NZ roads That's rather fast !! Ever plan on taking it to the drags ? Quote Share this post Link to post Share on other sites
gaijin 174 Report post Posted June 20, 2023 Yeah for sure it's nippy, stage 2 fbo was 3.3 so not hugely quickerto 100, Once it's up to speed i.e 80kms plus it's much quicker, with DSG and TVS tune it's something else. Definitely a license loser. Dragy GPS testing with a decent boost leak only got me a high 11 1/4. Shameful. Expect a 11 flat now that's all sorted 👍, on public coarse chip Mexican roads no prep of course. First project car that has an actual end to mods. Time for something more serious, the 1m. Then there are two more serious after that. Quote Share this post Link to post Share on other sites
elias 263 Report post Posted June 21, 2023 20 hours ago, gaijin said: Not a BMW photo but looking good as a family car tonight, now its cold itll be time to see/get the dragy times, the TCU tune feels really aggressive with solid larger turbo spool sounds. 0-100 still in 3.1 zone on a warm day on NZ roads, winter and wider front PS4S and semis on the back should/could improve a little, running 255/30/19 fronts with 235/35/19 rear, off square as per RS3 option. Slides around nicely now is that taken at milford mall? looks familiar haha not far from me Quote Share this post Link to post Share on other sites
gaijin 174 Report post Posted June 26, 2023 (edited) Yip the local suppie, High pressure injection being deleted Removed HPFP, add cover Removed index 12's Add SS blank plugs and hold downs, similar to the stock ones. Then forced into HP injector hole N54 Maxx ECU adapter on its way from Sweden, allowing me to run stock engine harness up to the adapter, then into Maxx Race ECU. Its NOT child labour, its work experience....time to strip the rears Edited June 26, 2023 by gaijin .... 2 Quote Share this post Link to post Share on other sites
gaijin 174 Report post Posted July 3, 2023 OK, so fuel tank is back in, Another fuel filter for the 8AN main feed, engine bay mounted, easy to reach Need some different fittings to attach 8AN to fuel rail, turning into some sort of meccano set, keep it simple stupid, Regulator mounted, one fitting needed for the return to reg from the rail, return to tank done New BMW Accessory Drive Belt Kit - 11287628652KT fitted, Brakes ready for cerakote, changed out the caliper bolts to 12.9 cap screws Ill keep working on the fuel system. Going to Port injection only means bigger than 750cc injectors, 1250cc's at 45psi arriving tomoz. Probably change out the chinese FPR to a turbosmart, keep things decent. 2 Quote Share this post Link to post Share on other sites
Cement 892 Report post Posted July 3, 2023 Looking sweet, not too late to go for the Speedflow custom colour anodised fittings... Just sayin 🤣 Quote Share this post Link to post Share on other sites
gaijin 174 Report post Posted July 3, 2023 (edited) Yeah darn, all black from now promise, just getting things to fit first before final order 🥴 Leftovers from another build from when xtasy and catchit were fashion Edited July 3, 2023 by gaijin Edit 1 Quote Share this post Link to post Share on other sites
gaijin 174 Report post Posted July 11, 2023 Maxx ECU N54 adapter arrived. You have to pay to play sheesh... This allows the use of the OEM engine harness to plug between the Maxx ECU race and the harness. Minor looms aside like coils and injectors. Pretty happy with the quality. 1 Quote Share this post Link to post Share on other sites
gaijin 174 Report post Posted July 11, 2023 Other work to date; EV6/USCAR injector harness made and installed 1M front carbon bumper extension/lip whatever they are called. Work to finalise the oil cooler mounts to lock them in well. Needed the front crash bar removed to install the LHS oil cooler bracket that isnt a 135i item, but a 335is OEM piece, fits fine. Hard to find tho. Also the little plastic retaining nut that sits inside the chassis frame rail. RHS oil cooler finished, apart from sealing in the air gaps to force air through the cooler, will get some seals and foam to close that up later. The LHS top mount needs to be fabricated to mount back to the frame rail, likewise the new oil bracket off the front crashbar/frame rail needs to be modified to mount the vertical plane of the cooler on. Ill prob rivnut x 3 into the steel bracket and bolt back to the cooler shroud. Moving to heavier duty territory with the coils, going R35 GTR using the PRP coil bracket. Lastly, brakes are almost cerakoted and done, colour sample here; 2 Quote Share this post Link to post Share on other sites
gaijin 174 Report post Posted July 12, 2023 N54 adapter for Maxx ECU installed to auto loom also converted to manual, removing the large round plug to transmission, replaced with the manual section of loom that has the reverse switch for the 6spd. 1st pic top side is 6M, lower loom on 1st pic auto loom section. Done apart from coils, inj and single O2 Extra auto guff not needed Next loom jobs, remove coil section and injector sections of loom, lastly plug for a single Bosch LSU 4.2 O2 sensor. That'll remove the twin bank scenario and O2 sensors burning up, itll go 6" past the turbine housing down in the dump pipe. 6M OEM loom into adapter; Lower two black plugs go into Maxx ECU Quote Share this post Link to post Share on other sites
elias 263 Report post Posted July 12, 2023 Awesome work! Did a similar oil cooler setup on my 135i, interested to see how you do the air ducting, yet to do that for my bumper, should provide an improvement in the effectiveness of the coolers. Mounted my coolers onto the frame rail ends, and into the radiator support where the ducting used to attach. (Oem oil cooler has since been removed). Quote Share this post Link to post Share on other sites
gaijin 174 Report post Posted July 12, 2023 Elias, looks good. In keeping with how the OEM coolers sit ala 1M and 335iS, leave the frame rails alone, no drilling FTW. Quote Share this post Link to post Share on other sites
gaijin 174 Report post Posted July 12, 2023 Cerakoted Burnt bronze C-148, good for 500+ deg C they don't do a clear above about 180deg C. But a super hard one with UV stability, non-yellowing, MC-160 is what they recommend for brakes and outside, external use. It'll keep the cheesy stickers from floating away. I didn't want to spray some supercheap auto paint over this, far too good for that. Waiting for the clear to come from states before the final coat and reassemble. Stickers are higher heat type. They look quite 'munnitions military, less gold than I was hoping for too. 👍 Rears wont get the re-build kit, as all seals were still soft n pliable, fronts were not, so get full treatment once cleared. Even started the Maxx Ecu file tweaks for the cars setup 4 Quote Share this post Link to post Share on other sites
elias 263 Report post Posted July 13, 2023 3 hours ago, gaijin said: Elias, looks good. In keeping with how the OEM coolers sit ala 1M and 335iS, leave the frame rails alone, no drilling FTW. yeah i agree, definitely wouldnt want to drill any holes. I just bolted my bracket onto the end of the frame rail using the some bolts. Didnt drill a single extra hole into the car just made the brackets to suit. Can sort of see it in the photo below if you squint. Main reason for making these brackets was to try place the coolers directly behind the 1m rep bumpers air scoops, which should make the ducting simpler. Brakes look awesome! Quote Share this post Link to post Share on other sites
gaijin 174 Report post Posted July 21, 2023 (edited) Prob the strongest spark I can get for the n54. Nissan r35 oem coils, B58/S55 BMW 2 step colder plugs to fit the coils. Modified by changing out the coil stalk with the platinum race products. They're much longer so that they reach and snap onto the plug tip. Plugs have a different tip to the n54 types, hence the change. Needed to stretch out the stalks internal spring so the coil resistor would fit snug. Loom is a universal type from PRP. Coils held down with prp bracket, fits well, sturdy enough. I avoided the anodized purple and went with black Edited July 21, 2023 by gaijin ... 1 Quote Share this post Link to post Share on other sites
gaijin 174 Report post Posted July 25, 2023 (edited) Spent the day getting the brakes back together, taken the whole day, after getting the clear coat and curing for a few days. lots of wire brushing crusty brake bits. Orbital sanded rust off discs. All connected up with hoses so ready to be bled. Used new M12 12.9 cap screws to mount the calipers to the brake mounts Edited July 25, 2023 by gaijin pix 5 Quote Share this post Link to post Share on other sites
Ooonst 4 Report post Posted August 2, 2023 Insane build. I'm not sure I could get this much work done on mine in 2 lifetimes. Quote Share this post Link to post Share on other sites
gaijin 174 Report post Posted August 2, 2023 I hear you Ooonst, ultimately we create our destiny, mine I hope will be all four project cars lined up beside each other, and all finished/working Im itching to restart working on no.3 of 4, reimagining it a little more from before, a BMW DCT behind a Toyota 5s bottom end, 3s Gen 5 Dual VVTi head, cnc'd, 2.3l all forged mega motor that I've already built. All wrapped into a street Celica 1972. Weight will be around 850kg, with the same in hp. This is helping me to move more on the BMW, a simpler project, but always learning Quote Share this post Link to post Share on other sites
