F80 M3 S55 Single Turbo Build

[chetrickerman]

Schrick cams installed! So far its running well, just waiting on SPEC to ship my clutch out since my OEM clutch is having issues.

[DeezBluBallz]

Originally Posted by chetrickerman

Schrick cams installed! So far its running well, just waiting on SPEC to ship my clutch out since my OEM clutch is having issues.

Who are you using to tune it w/those cams?

[chetrickerman]

Originally Posted by DeezBluBallz

Who are you using to tune it w/those cams?

Myself, of course

[chetrickerman]

Well I finally found the issue with my clutch, it looks like the dual mass flywheel failed, along with one of the plates of the pressure plate return spring.

But thanks to a great seller on here, I was able to find a clutch after over a month of searching and I installed it. I also installed the RevShift dual mount diff plate and front bushings for the rear diff since the driveshaft was disconnected from the transmission. Now the Rear diff should be secured extremely well, prohibiting any unwanted movement which should allow the rear to feel more planted. I also upgraded to a stainless steel throw out bearing pivot pin and changed all of the drivetrain fluids.

[chetrickerman]

FMIC incoming! I am using an 18x12x4.5 CSF bar and plate core. Yes it is heavy, but I will upgrade to a tube and fin core later.

I also removed all of the water to air setup and weighed it to compare to the air to air. With both heat exchangers and all tubing empty, its almost 40 pounds. I will fill the system and re-weigh it to find the operational weight.

[chetrickerman]

For anyone who cares, this is the weight with the charge air cooling system filled with water, looks like there is about 10 pounds of water in the system.

[b_w.]

interesting. what is the goal with this change?

[chetrickerman]

Originally Posted by b_w.

interesting. what is the goal with this change?

The main reason is that its lighter and more simple.

[DeezBluBallz]

Is that a single inlet wagner intercooler? Are you selling it?

[chetrickerman]

Originally Posted by DeezBluBallz

Is that a single inlet wagner intercooler? Are you selling it?

Yes sir, it is sold already.

[chetrickerman]

Small update, I got the intercooler end tanks mocked up out of cardboard, there will be an internal air guide to direct air so the whole core is used. The charge pipes are just tacked for now while I verify fitment and get everything where I want it.

Next I will be tracing the cardboard shapes onto 0.090" thick aluminum. Then I will have to make a new coolant expansion tank since the OEM reservoir wont fit in its normal location anymore.

[sly1types]

Originally Posted by chetrickerman

Small update, I got the intercooler end tanks mocked up out of cardboard, there will be an internal air guide to direct air so the whole core is used. The charge pipes are just tacked for now while I verify fitment and get everything where I want it.

Next I will be tracing the cardboard shapes onto 0.090" thick aluminum. Then I will have to make a new coolant expansion tank since the OEM reservoir wont fit in its normal location anymore.

Surprised to see you going air/air. Is that just to save weight? What are your thoughts on IATS? Do you do any road racing with your car?

At this time can you elaborate on the XDI pumps you used? Are they the EVOs? are they just bolt in? or do they need the rail like Nostrum? I am looking at those or the Dorch lift kit.
https://xtreme-di.com/product/n55-s55/

[chetrickerman]

Originally Posted by sly1types

Surprised to see you going air/air. Is that just to save weight? What are your thoughts on IATS? Do you do any road racing with your car?

At this time can you elaborate on the XDI pumps you used? Are they the EVOs? are they just bolt in? or do they need the rail like Nostrum? I am looking at those or the Dorch lift kit.
https://xtreme-di.com/product/n55-s55/

Everyone I have spoken with that has already gone A2A says their IAT's are more consistent and better than ever. Also, so far its taking around 25 pounds off the very front of the car. Yes I will be doing track days with my car.

Yes, I am running the XDI Evo pumps and they have been flawless. The build quality is superb, they bolt right in (easier install than the lift kit). As far as needing an intake manifold spacer, I cannot say since I'm running the EOS intake manifold with their phenolic spacer.

[chetrickerman]

The intercooler and charge piping is all welded up. Next is mounting it to the car and pressure testing. In the third picture, you can see the air guide I welded inside that splits the airflow in half and guides it to the lower half of the core using a pretty smooth radius that way the whole core is used to cool the air.

[Oliver Queen]

Originally Posted by chetrickerman

The main reason is that its lighter and more simple.

I ended up opting to stick with the stock cams on the motor - did you notice any performance improvements / sound differences?

[chetrickerman]

Originally Posted by Oliver Queen

I ended up opting to stick with the stock cams on the motor - did you notice any performance improvements / sound differences?

My engine doesn't sound any different with the cams, but I can definitely feel a difference in the top end power, it wants to eat! Daily driving the engine feels like stock, I really like these cams.

[chetrickerman]

With the new charge pipe routing, the OEM coolant expansion tank would not fit, so I had to make a new one. The total coolant volume in the S55 is 13.9 liters, and the expansion tank should be at least 10% of that volume, so I made a 1.55 liter tank out of 4.5 inch tubing. I used a mishimoto 28 psi radiator cap, and a sight glass so I can see the level of coolant.

Once I finished that, I could move on to the extremely important step of leak testing. I assembled the charge system off the car, capped the throttle body with a 3.5" x 1/2" thick aluminum plate, and a boost leak tester welded to a vanjen flange. I pressurized the system to 50 psi, found a couple small leaks, welded them closed, and washed all the soap off the tubing/intercooler.

Next step is final assembly and putting the rest of the car back together

[Phat55]

Love this build!

[funk323]

I would try my best to make sure the intake was being fed fresh air, where it is now you will see high IAT.

[chetrickerman]

Originally Posted by funk323

I would try my best to make sure the intake was being fed fresh air, where it is now you will see high IAT.

Thanks, but when boost comes on, the IAT is very close to ambient temps. When the methanol is active, the IAT actually drops below ambient temps.