[M.Blacktree]

Just a side note: It's time to start planning the turbo upgrade. There isn't much left to do, that doesn't involve a turbo. After the polycarbonate windows are installed, I'm going to make a foot plate for the driver side floor, and the car is basically good to go. Yeah, there's other stuff I could do, like more chassis bracing or a LSD. But that stuff can wait.

Some of you were probably wondering when I was gonna get around to this. But I wanted to get the chassis and suspension sorted out first. Anyway, I'm thinking of using a cheap turbo manifold with a single "smedium" turbo. The target is ~350 HP, so a GT3076 or T3/T4 hybrid should be plenty. We're also going to convert the fuel system to E85.

That said, the route I plan to take is pretty well traveled. There are several turbo M54 builds on youtube. I'd like to do something to set this build apart from the rest. Maybe use an air-to-water intercooler? I haven't seen anyone do that in an E46.

Thoughts? Opinions? We have some time to talk about it. Once again, our goal is ~350 HP. So don't get too crazy. 😎

 

[mcollinaren]

Just a side note: It's time to start planning the turbo upgrade. There isn't much left to do, that doesn't involve a turbo. After the polycarbonate windows are installed, I'm going to make a foot plate for the driver side floor, and the car is basically good to go. Yeah, there's other stuff I could do, like more chassis bracing or a LSD. But that stuff can wait.

Some of you were probably wondering when I was gonna get around to this. But I wanted to get the chassis and suspension sorted out first. Anyway, I'm thinking of using a cheap turbo manifold with a single "smedium" turbo. The target is ~350 HP, so a GT3076 or T3/T4 hybrid should be plenty. We're also going to convert the fuel system to E85.

That said, the route I plan to take is pretty well traveled. There are several turbo M54 builds on youtube. I'd like to do something to set this build apart from the rest. Maybe use an air-to-water intercooler? I haven't seen anyone do that in an E46.

Thoughts? Opinions? We have some time to talk about it. Once again, our goal is ~350 HP. So don't get too crazy. 😎

Get an rsi turbo manifold. I know you already said you bought a manifold, but if you really wanna stand out, ditching the v6 pickup truck noises of a log manifold in favor of an rsi manifold will surely make you stand out. They sound fantastic. I haven’t seen an e46 build on YouTube that featured one of them, so it’ll make you stand out. Granted, most people don’t care as much about exhaust sounds as I do so you may not care to invest in such things. But this is what it would sound like if you got it:

 

[The_Fixer]

Just a side note: It's time to start planning the turbo upgrade. There isn't much left to do, that doesn't involve a turbo. After the polycarbonate windows are installed, I'm going to make a foot plate for the driver side floor, and the car is basically good to go. Yeah, there's other stuff I could do, like more chassis bracing or a LSD. But that stuff can wait.

Some of you were probably wondering when I was gonna get around to this. But I wanted to get the chassis and suspension sorted out first. Anyway, I'm thinking of using a cheap turbo manifold with a single "smedium" turbo. The target is ~350 HP, so a GT3076 or T3/T4 hybrid should be plenty. We're also going to convert the fuel system to E85.

That said, the route I plan to take is pretty well traveled. There are several turbo M54 builds on youtube. I'd like to do something to set this build apart from the rest. Maybe use an air-to-water intercooler? I haven't seen anyone do that in an E46.

Thoughts? Opinions? We have some time to talk about it. Once again, our goal is ~350 HP. So don't get too crazy. 😎

I am a fan of Turbo cars. I have an N54 that I just had custom turbos built for. For the M54 though I would be more prone to supercharging as they seem to be easier to install with less hassle and there are less problems.....depending on the kit you get. Obviously you would go for quality components.

There are many turbo'd M54's running around though with no issues. So.... you know it is very doable. Instead of air to water intercooler, which is cool....literally lol, maybe meth injection in the charge pipe instead. Works really well in dropping intake temps on boost.

If you want a very quality custom built American made turbo that will last you want Rob and RBTurbo. This guy who made mine has decades of experience and the latest in millions of dollars turbo making tools. You got to call him and talk to him before he'll consider taking your order. I spent over two hours with him on the phone the first time I called him because he wants to know your build to the last detail.

 

[M.Blacktree]

Get an rsi turbo manifold. I know you already said you bought a manifold, but if you really wanna stand out, ditching the v6 pickup truck noises of a log manifold in favor of an rsi manifold will surely make you stand out. They sound fantastic. I haven’t seen an e46 build on YouTube that featured one of them, so it’ll make you stand out. Granted, most people don’t care as much about exhaust sounds as I do so you may not care to invest in such things.

I agree about the engine sound. And would really like to keep the sound of the long-tube headers. But so far, all I've seen for low-mount setups is log manifolds. I forgot to mention this, but am looking to go low-mount for better weight balance. I did find a low-mount "bundle of snakes" manifold for the S54. Maybe I could cut off the flange and weld on a M54 mounting flange. But at $1700, that's an expensive experiment!

BTW, here's a link to that S54 manifold. It's a work of art. DOC Tubular Bottom Mount Manifold

Anyway, it looks like I'll have to get used to my car sounding like a tractor. Unless there's something I missed.

I guess another option would be a remote turbo (i.e. rear mount). Then I could keep the long tube headers. A google search turns up a few forum threads with people asking about it, and everyone else telling them not to bother. LOL. The search also turned up a few companies that specialize in rear-mount turbos. Maybe I can pick their brains.

 

[mcollinaren]

That s54 manifold you showed a picture of will still sound like a truck. It’s still super unequal length with each cylinder having a shorter runner than the last. I dunno how much of a fabricator you car, but here’s a pretty cool idea of a low mount turbo manifold I saw a few months back. The guy who made it had a rhd car and didn’t have space with the steering column for a conventional low mount manifold. This big horn ram looking manifold would still give you that equal length goodness. Now this one situates the turbo where the ac compressor once sat, but if you wanted to mimick said design and keep ac you could probably just flip where the turbo mount is to the back of the engine.

 

[M.Blacktree]

That's pretty ingenious!

 

[M.Blacktree]

Good news! I got a chance to do some full throttle launches, and the transmission is shifting great! So it seems the transmission issue is solved. It was the gear selector switch all along.

But after the spirited driving, the oil pressure dropped and the valvetrain got noisy. I shut off the engine, and let it cool off for a bit. When I restarted it, the oil pressure was low but good enough to drive home. So I babied it back to the house. I pulled the oil filter, to see if there was any metal shavings in there. I didn't see anything definitive. But the filter had a bunch of carbon buildup.

This has been an ongoing thing. Ever since the engine flush, lots of carbon buildup has been making its way into the oil filter. Will it ever end? Who knows. But for now, I'll just toss another filter in it.

 

[The_Fixer]

Good news! I got a chance to do some full throttle launches, and the transmission is shifting great! So it seems the transmission issue is solved. It was the gear selector switch all along.

But after the spirited driving, the oil pressure dropped and the valvetrain got noisy. I shut off the engine, and let it cool off for a bit. When I restarted it, the oil pressure was low but good enough to drive home. So I babied it back to the house. I pulled the oil filter, to see if there was any metal shavings in there. I didn't see anything definitive. But the filter had a bunch of carbon buildup.

This has been an ongoing thing. Ever since the engine flush, lots of carbon buildup has been making its way into the oil filter. Will it ever end? Who knows. But for now, I'll just toss another filter in it.

Hmmmmm......

Send your oil into Blackstone for an oil analysis.

 

[M.Blacktree]

I'm pretty sure the oil analysis would just confirm this engine is on borrowed time. Actually, before the turbo upgrade I should pull the engine and go through it. Maybe do an "I do cars" style tear-down.

 

[mcollinaren]

I'm pretty sure the oil analysis would just confirm this engine is on borrowed time. Actually, before the turbo upgrade I should pull the engine and go through it. Maybe do an "I do cars" style tear-down.

How about you boost the engine, blow it up, then do the “I do cars” style tear down? Because we love to see some carnage

 

[M.Blacktree]

It's tempting.

That said, there's a guy on youtube who does turbo upgrades and blows up the engine a few weeks later. I don't think he really knows what he's doing. I don't wanna be that guy.

 

[kylanjohnson]

It's tempting.

That said, there's a guy on youtube who does turbo upgrades and blows up the engine a few weeks later. I don't think he really knows what he's doing. I don't wanna be that guy.

It's only money 😉

 

[M.Blacktree]

The video regarding the transmission selector switch is ready to go. It will premiere 10am EST tomorrow.

 

[M.Blacktree]

The video on the floorboard restoration is up! That said, the video is a little rough around the edges (or rather, more than usual). I'm learning to use new video editing software. After I get a feel for it, the production value should improve.

Previously, I was using Windows Movie Maker. No joke. It's easy to use, but very basic. I need something with more features, so I upgraded to Davinci Resolve. It has orders of magnitude more features, but there's definitely a learning curve.

Anyway, here's the video. Have a great weekend!

 

[swordsman11868]

I'm glad to hear that ALL testing occurs in Mexico. Keep up the great work!

 

[RustyRoadster]

The video regarding the transmission selector switch is ready to go. It will premiere 10am EST tomorrow.

I just did this procedure with my coupe a month or so ago. The Cog has not returned as of yet. I didn't have that corrugated tubing to replace around the wire loom and wish I had done this.

 

[t.er]

Interesting how the driver's side floor plug was gone from your car, mine also partially popped out and I too fibreglassed that hole as well. My passenger's side however was ok. I went ahead and put some seam sealer on all plugs I could find underneath the car to seal and prevent them from coming out again

 

[M.Blacktree]

Just a quick update: I made a floor plate for the driver side. With the carpet and padding removed, the gas pedal sits about an inch above the floor. And that can make it difficult to operate the gas pedal. Plus the floor isn't flat. So I decided to make a floor plate.

At first, I thought of buying one online. But the aftermarket floor plates are around $150. That's a lot to pay for a piece of sheet metal to put your feet on. So I made something from a sheet of 6mm (1/4") plywood, and scrap lumber.

I used a piece of cardboard as a template. I whittled away at the cardboard until it fit, then traced it onto the plywood. And I attached some pieces of scrap wood to the underside of the plywood, to stiffen it. Then I applied 2 coats of water sealer. And I put a piece of traction tape on it, where my feet will be. See photos below.

Total cost for the project was under $20. Now I have something to rest my feet on. And it's easier to operate the gas pedal.

 

[cigma2312]

Awesome project, I was over here happy as a clam I got my spark plug back into the engine. This dwarfs that in complexity!

 

[M.Blacktree]

Just a quick side note: Lately I've been getting an intermittent "check fill cap" warning light. Sometimes it'll come on when I start the engine, then go off after a moment. Sometimes it doesn't. I'm assuming it's related to the evap system? I tried removing and reinstalling the gas cap (with 3 clicks), and it still gives the warning light on occasion. But no check engine light, just the fill cap light.

To be honest, I was thinking of deleting the evap system anyway. In another thread, somebody said the evap system weighs 8 pounds. That's not a huge difference, but every bit helps. I've already picked all the low-hanging fruit, so to speak. So now we're shaving off a few pounds at a time.

I suppose I could replace the gas cap, although it works fine. Seems like a waste of money to replace something related to the evap system, when I'm going to delete it anyway. But then again, a new gas cap is only about 10 bucks. Hmmm...