BMW 325TDS Project Smoke Machine

[TorqueWorks]

Another Diesel Drifter, maybe not to the extremes as the merc build but still a slider..


After getting my 320d I decided I couldnt have a rwd without feeding my craving for sideways, and not wanting to abuse my new one I had to get another one that i could go mental with. Feeding my hatred for sparkplugs and love of german machines a 325TDS was the obvious choice. Owly went parts with me on this project.

2.5L turbo Diesel, 6Cyl giving out 140Hp & plenty of torque. The bosch pumps in these are electric controlled & I can work Black Magic on these ;)
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-09-22-410_zps534ae7fd.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-09-22-411_zps8b00f593.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-09-22-412_zps52945ade.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-09-22-413_zpsd3c785cb.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-09-22-414_zps42e6baf5.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E46%20320d%20M%20Sport%20Estoril/2012-09-23-415_zpsbb760595-1.jpg

got it jacked up & checking all the bushings in the back, all seem nice & solid. Rear Left wheel bearing is fucked tho had it out to 155MPH up on the axle stands
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-09-23-419_zps3a483d04.jpg

up to the front then, power steering pump im not so sure about, so ill probably flush the system & see. Fan belt tensioner is a bit stiff aswell so ill open it up & see.
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-09-23-420_zpsadfa9bee.jpg
front mount intercooler & hosing & that seem in good nick so thats good.
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-09-23-421_zps4eb73754.jpg
feeling the clutch is going to give up soon enough owly already managed to get it slipping. Especially when I get this throwing out some daecent power figures pluming black smoke. looks easy enough to get the gearbox out so happy about that.
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-09-23-422_zpsfdfe977c.jpg
wishbone bushes are grand, not so sure about the balljoints tho.
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-09-23-423_zps67d9aa7b.jpg


will be fitting a Hydraulic handbrake & maybe even a biasing valve. welding the diff, lower it a bit with harder springs to sharpen the handling, clean out the air intake & EGR block, turning it up until theres nothing but Pure Pollution coming out the back, decat & maybe twin exhausts or a side exit.

Agri Spec Diesel Slider FTW

[TorqueWorks]

right, owlys cars still causing me headaches, theres always somethin!

anyways we tore into it briefly this weekend
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-05-439.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-05-440.jpg

opened up & washed out
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-06-441.jpg
welded up
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-07-446.jpg

and the rear hub taken off & wheel bearing changed out. hub is such an odd shape its a bastard to keep straight on the press
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-07-447.jpg

went stripping & trying out new toys, namely shane going mad with the air chisel. the plasma cutter or the grinder were going to set the interior up if we werent careful. Couldnt believe how easily it cut through the plate into the boot
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-07-443.jpg

then another of owly's notions, a cold air feed through the fog light
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-07-444.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-07-445.jpg

[TorqueWorks]

settling into the slow side of the build now, didnt have much time this weekend with loading up & setting up for tractor pulling :D

a brake line flaring tool we made a while back
gona be important for this bit of the build
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-07-448.jpg

how are we gona work the hydro handbrake
http://i956.photobucket.com/albums/ae49/buzz2753/handbrake-1.png
first things first, the clutch master cylinder we're using (0.625) had a reservoir on top & is designed for drip feeding for adjusting clutch position. the cylinder had to be opened & the feed bored out to take the flow of brake fluid through it for in-line use, and we also had to thread it to take a bolt that we would bore & make a brake line fitment out of
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-13-454.jpg
machining the bolt we are using as a reducer. A blind 10mm hole had to be bored & tapped, followed by a through bore of 3mm. This was to make a seat for the flared brake line.
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-13-450.jpg

made up a mounting bracket for the master cyl on the milling machine
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-13-452.jpg
then a mounting bracket to go onto the car
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-13-455.jpg
and decided where I was going putting it
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-13-451.jpg
then an adjustable leaver system
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-13-456.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-13-457.jpg

never got it finished, need to weld on guide rails for the leaver & bend the leaver to a nice position for the driver.

[TorqueWorks]

Picked these up in Trim last night, 6cyl 40mm lowering springs
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-15-462.jpg

[WayneR33]

Will be keeping an eye on this have an e34 525 tds myself. The tuning chips off these are a very good job and only around €100 endtuning.co.uk

[TorqueWorks]

Will be keeping an eye on this have an e34 525 tds myself. The tuning chips off these are a very good job and only around €100 endtuning.co.uk
running my own chip on this, cost to me = a lot of hours figuring out

[WayneR33]

Ha, evry mod is it?

[rps13Carlow]

Really good job. Just curious, what lathe have you got?

[TorqueWorks]

Will be keeping an eye on this have an e34 525 tds myself.
actually have one myself aswell :P an auto, pure gangster looking yolk



Really good job. Just curious, what lathe have you got?
2 of them would have to check at the weekend



Anyways continuing on slowly
Bought this lastweek to rob bits off & break it
E36 318IS Coupe M Sport, few tasty bits on it

Anyways, stealing some bits off it at the weekend & being a petrol and my Ban on spark plugs, the engine was not coming past the door :P
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-20-490.jpg


anyways, Figuring the ECU & Pump out what pins do what from the schematics to make up my chip
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/BOSCHBMW.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-21-493.jpg

EGR & Manifold cleaned out, Trailing arm bushings re-fitted now too

After that didnt get much done, & with tractor pulling going off again next week its not looking like much will be done this weekend coming either, Fiddling diesel pumps in tractors instead :D

[TorqueWorks]

after a bit of tractor pulling on sunday and lungs filled with black smoke it gave us a bit of motivation to get this going ASAP on monday, early start & late finish

got our wires pulled from the pump, and then the manifold went back on sunday night to give the gasket sealer chance to set.. all painted up
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-29-537.jpg

diff put back in, lowering springs fitted & camber adjusted to the max... tracking at the min is severely toed in, sort that nextweek maybe
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-27-511.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-27-513.jpg


stripping the original seats & interiorinterior. The weight of the factory seats is something else..
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-28-531.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-28-532.jpg


and just another slight mod to the Hydraulic handbrake, guide rails for the leaver. almost done with this now & needs to be fitted
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-10-29-533.jpg

[TorqueWorks]

got impatient then and wanted to see some smoke, had an initial go at starting the car & had hardship with a broken return hose on cylinder 5, airlocking constantly. damaged it while removing or re-fitting the manifold..

Once that was sorted we got it started but running rough, air coming through from before the diesel filter, so after some head scratching we discovered that the lift pump in the tank was not going, when we gutted the interior we broke the negative wire that does be grounded to the chassis.. got that back in & within 5 seconds it started running like clockwork yet again :D so simple but enough to burst your head for a while

anyways, with it running.... time to chip it up :D BLACK SMOKE :D poor Karen got a mouthfull of soot as she showed up just as we were getting it running right
BMW 325 TDS Custom chip - YouTube (http://www.youtube.com/watch?v=3yPUU3qHe0o)
http://www.youtube.com/watch?v=3yPUU3qHe0o

Brought it out for a spin, the power difference is MENTAL, spins in first second and third. Power band is nowflawless right to 5000 revs, and there is potential with this chip to go a touchien further.. I think we found the limit of this clutch, was half worn to start with tho we reckon.. Next is screw the boost a bit, but Lovin this smoke :D

[grange]

Are poor environment :(

[TorqueWorks]

Got the rear bumper on & the brakes setup through the Hydraulic handbrake :D


I'll update that in a bit, but we tested it out on the slab saturday night :D fan belt tensioner kept hopping into service position & ended up breaking... so... we need a new one of those
2000-3000 revs in 2nd gear not a bother :D Torque FTW... We did notice the smoke died away while she was under pressure but the power did not... must be using all that extra diesel, so when we screw the boost it will take a hell of a lot more... the clutch is also definitely fucked so that'll be done sharpish

www.youtube.com/watch?v=Ngh2GHGumP8
www.youtube.com/watch?v=Ngh2GHGumP8

[TorqueWorks]

anyways, the other bits we got done was the Hydraulic hadbrake... shorter throw on it than I was expecting being honest, so just change the angle Im pulling it at now to get more leverage.. anyways fitted, bled & working with no leaks thank god

http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-11-02-541.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-11-02-544.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-11-02-545.jpg
and cut a bicycle handle bar off with the grip, ovaled it & cut it up the middle to make a nice handle & then the grip slides over:D
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-11-03-548.jpg


and we went up & picked up the bumper, and a few more spare tyres & alloys
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-11-03-549.jpg


then ofcourse... a few Rings :D that i posted earlier.. last time we were diffing like that was with Mark G in his DX... Gone but never Forgotten :/

[TorqueWorks]

Tackeled the cluch saturday, as we thought the clutch disk was well worn... and the size of the splines on the cluch, no fear of them breaking :D

Ramps on the Lowloader made some job as a partial lift, didnt go too high either so the jack would be able to support the gearbox as we took it out
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-11-17-566.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-11-17-567.jpg


Bad news however is that our dual mass flywheel is totally fucked and even warped.. so need to get a 2nd hand one and do a solid conversion on it

[TorqueWorks]

Just noticed I never updated this, An original clutch cannot stick the torque that we're putting through this, so I ordered a Ceramic clutch and uprated pressure plate... waiting impatiently

I also got this since
pic of the Boost controller, brand new belt tensioner (keep the belt from hopping into service position.. And some Go Faster tape for a German flag :D
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-12-02-589.jpg


patience ran out waiting for the ceramic clutch, went mental and made a front splitter and a rear spoiler

gotta say I really like the splitter how it came out, finished in carbon black metallic paint
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-12-30-622_zps90e21877.jpg

[LarZ]

Nice thread! I'd love to be this talented when it comes to working on my drift car. Can't wait to see this on track

[TorqueWorks]

Nice thread! I'd love to be this talented when it comes to working on my drift car. Can't wait to see this on track

Ya might not be waiting too long ;) See ye sunday




EoinK got this for us & dropped this off at the weekend :D Brand new lovely feel to it, gotta machine up a boss kit for it next at some stage
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-11-11-554.jpg

Propper German Quality boost guage up to 3 Bar
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2012-11-12-558.jpg

serviced it too, new filter & a good quality 5w30

[TorqueWorks]

and let there be more updates to this at long last

clutch finally arrived so prepare for more video's and updates
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-01-12-663_zpsdd16b7c8.jpg

The pressure plate we got was OEM, so we put in the old one cos im going to fuck this one back at them

we didnt fit any of the bearings we got with the kit, they are supposedly shite. the release bearing was definitely a dose of shite its not a bearing atall so that went in the bin

anyways, clutch disc lined up
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-01-24-700_zps14df78fb.jpg
and a bit of lubricant on the splines
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-01-23-697_zps2c2e070e.jpg


got it out and going yesterday then spent 5-6 hours constant and the temperature never rose once, and only burned a half a tank of diesel. crank shaft seal doesnt seem to like the 5w30 castrol I fed it, too light :/ bit of a seep every now & then.. that's the next thing to do. so whole lot off again :/... Other than that, the bite in the clutch is actually feckin unreal & getting better as it beds in.... so we turned it a bit more ;) still haven't screwed the boost & we've 3000 revs of usable rev range, we were diffing at 2k revs yesterday steady even as the yard dried out, infact you can see that in the vid :D

anyways, video:
BMW m51 325 TDS diesel diffing - YouTube (http://www.youtube.com/watch?v=edqcf4XQNEc)

http://www.youtube.com/watch?v=edqcf4XQNEc

[TorqueWorks]

went messing again at this yesterday

Needed a boss kit for the steering wheel, so we cut the centre out of the old one, machined the face off on the lathe and bored the holes on the C&C milling machine to get them in the right spot. tapped them then & bolted the steering on :D worked out better than I was expecting
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-02-16-756_zps72ecd301.jpg
machined face
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-02-16-755_zps3694d400.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-02-16-757_zps447fcc92.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-02-17-762_zps12d776c8.jpg


screwed the boost up to 1.5 Bar
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-02-17-759_zpsd5827147.jpg


oh, and new buckety seats :D
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-02-17-763_zps52626b57.jpg


then the crank shaft seal finally caused us more hassle :/ disc, flywheel and pressure plate got contaminated..
next step now is machine the face of the flywheel, take the step down a bit while we're at it to make the disc more on/off.. and use the new pressure plate we got
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-02-17-764_zps800d8c48.jpg
the culprit, going to get a new seal in Abbey Seals in dublin durding the week
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-02-17-765_zps879b83c9.jpg
oil everywhere
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-02-17-766_zpsab79db36.jpg



anyways... sickened about the disc getting contaminated, probably get it re-lined now... always feckin something

[TorqueWorks]

Right
Re-lined ceramic pads on the clutch, 1mm thicker overall than the previous disc, new training arm bushings for front and back, and a new crankshaft seal that now I think im going to return & upgrade for a high pressure high temperature seal to cope with the increased crank case pressure
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-02-23-776_zps6ad9c00b.jpg
then we filled the grooves in the bushings with mouldable plastic
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-02-23-777_zps2cd321df.jpg
skimmed the flywheel to remove contaminants of oil
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-03-02-791_zps9434078a.jpg
and a reinforcing bar with a jacking point on the rear
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-02-23-778_zpsbca8266e.jpg

lot of work to do for its first big trial

[TorqueWorks]

so rain today, back at it & Found why the crank shaft seal has been leaking:

pulled the rocker cover off to find out where the breather was & why the crank pressure was building up causing oil to be forced out the crank shaft seal
delighted to find the timing chain as tight as fuck, and the cams all perfect no signs of any damage so alls good in that department
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-03-06-806_zps6e8840c3.jpg

now onto the rocker cover itself where the breather is behind a splash guard, so with the splash guard removed & I discovered the wire mesh that is clogged to shite with oil, which I think Ill be removing altogether since theres baffles aswell, its a bit overkill & causing restrictions.. but I also noticed this plastic tab shoved down in the compartment of the vent itself, restricting flow... no wonder pressure is building, that tab is marked by the Red arrow, and the half mile of a metal gauze filter
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-03-06-804_zps6b6d8d9f.jpg

the tab again marked with red, and the yellow arrow showing the vent out into the air intake downpipe towards the turbo
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-03-06-803_zpse450ff4a.jpg
and the tab will certinally not be going back in
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-03-06-805_zps80ffbc5e.jpg


im contemplating whether to remove the gauze or part of it just to catch oil, but then again the splash guard completely seals 95% of the oil anyways.. or maybe an oil catch can and then straight out to the air.. Il think about it for now


went removing the front hubs & wishbones to extend both for camber & more lock... more to come tomorrow
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-03-06-808_zps471c8cb5.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-03-06-807_zpsbbaa933d.jpg

[TorqueWorks]

shortened the eye for the track rod on the hub 10mm, which makes it lock quicker and further, welding rods used were 29.9 rods very dear cunts at 2.30+vat each but a real clean weld, V'd it out & built it up well so tis very strong
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-03-07-814_zpsc43e289d.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-03-07-819_zpsbf368ec4.jpg

extended the wishbone 30mm for more camber
modified vs original
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-03-07-815_zpsb5311955.jpg

and how we extended them
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-03-07-817_zps89c79aef.jpg

re-track the car next & get a photo of how it looks on the car

[TorqueWorks]

No shortage of lock now
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-03-08-820_zps6a98fc5a.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-03-08-824_zps5ad6ce22.jpg

and a bit of camber
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-03-08-823_zpsa6d98554.jpg

[TorqueWorks]

Attacked the back arches to take 5 series alloys, cut the arch out & stuck on overfenders
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-03-20-872_zpsd089b9d8.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-03-25-892_zps86547095.jpg


another project shane went working on... S/S tipped Side Exit Exhaust :D
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-03-25-894_zpsec1b66b2.jpg


and the hassle... Clutch that we got re-lined after our last bout of crank shaft issues, new seal fitted.... and not enough gasket sealer :/
the new clutch disc is 1mm thicker than the previous
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-03-22-879_zps066e137c.jpg
and the freshly skimmed flywheel, Forgot to mention we had 0.5mm taken off the step.. which gives the effect of an even thicker clutch disc. This brought it up to almost the equivelant of a full thickness clutch disc giving it Waaaaaaay more bite than before
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-03-22-880_zps33923cca.jpg
the performance blue paint on the new pressure plate now that the old one was contaminated with oil
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-03-22-881_zpsaa75e78e.jpg
cleaned the bell housing out
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-03-21-877_zpsc11829ca.jpg

put the whole lot back together & was grand, everything ready to run, just bolting back up the started a nut fell down behind the flywheel, and gearbox had to come out enough to get the bolt out.. That was grand, until we put in the slave cylinder and the pin went above the fork unknown to us & burst.. putting brake fluid everywhere... gearbox back out yet again :cry:

http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-03-23-883_zpsc90e03be.jpg
pulled in another iS and stole the slave cylinder out of it, along with stealing the alloys off it had an awful problem taking off lock studs with no key for them
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-03-23-882_zps9c7e36bc.jpg


we thought that was grand cleaned the brake fluid out of the bellhousing & threw the lot back in yet again.. Started it up, brought it for a hard spin & came back in to find oil pouring out of the gearbox yet again... this was 10pm saturday night, proceeded to take out the gearbox yet again & found that the cunt was leaking out along the edge where the sump meets the block where we didnt put enough sealer... sealed it up & had the lot back in by midnight.. problem was that that gasket sealer takes 24 hours to cure fully, but it was due to do its first round on the track at 9 the following morning...

spent until 2am sorting out tyres & doing the final preps for the track day
welded on the remains of one of the wishbones we cut up for a towing eye
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-03-25-895_zpsf06ff731.jpg
also moved the battery to the centre of the boot just incase we decided to crash the back into something or someone.. very likely with two noob drifters at the wheel

it also took longer to load the car onto the car transporter without turning on the engine than it did to take out & put back in the gearbox

[blusrule]

Savage custom work going on here, it's the only way with the bmws! Think I saw you in Tynagh at the last driftfest?

[TorqueWorks]

Savage custom work going on here, it's the only way with the bmws! Think I saw you in Tynagh at the last driftfest?

Yep ya did.. may aswell continue from the beginning


Tynagh Superdrift 24/3/13
Set off at 5am with just little over 2 hours sleep :(

as expected the crank seal gasket started throwing out a bit of oil but not much so we kept going... by the end of the day & a gallon of oil later we were still going with 2nd gear, 3rd was slipping the clutch which is contaminated yet again.. The joys


Anyways I had an absolute ball, everyone was dead on & had fun polluting the place & blackening the track.. Came home as black as a coal miner & fairly delighted with the car.. Pure addictive Bring on the next day :D

anyways... Blackened the track :D
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/892875_509328509123889_836479374_o_zps8655d54b.jpg
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-ash4/484693_10200620331658279_97046613_n.jpg
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-snc7/601196_10200620337178417_1110941799_n.jpg


more pics
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/893661_372248939557978_50129002_o_zps2b4f491f.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/883278_145500502285131_250571463_o_zpse5a50ba4.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/180999_432150233544276_2007576514_n_zps450741f6.jp g
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/53729_305466069582008_1476264927_o_zps6c9d362c.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/5954_432116780214288_1961875879_n_zps576949c2.jpg


In terms of drivability, never once used the hydraulic handbrake or clutch kicked, just floored it & the massive amouts of torque spun the tyres instantly :D Engine is veeeeery responsive to the accelerator plenty of power :D Delighted with the car apart from the seal which I must now sort out.. Theres a lot of body roll, so I think our only choice now is coilovers..

[TorqueWorks]

Shane decided to get a petrol cunt of a thing for the track.. Continuing my ban on sparkplugs, he had to shove it in a shed in his own place
http://i872.photobucket.com/albums/ab288/nosmokenopoke/Shanes%20E36%20323i/2013-04-12-932_zpsb0dee848.jpg

plan to fit M50 manifold & chip er up


threw a bit of weld in the diff

then we made a straight through for it.. sounds mental now :D
http://i872.photobucket.com/albums/ab288/nosmokenopoke/Shanes%20E36%20323i/2013-04-12-934_zpsbb8b8106.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/Shanes%20E36%20323i/2013-04-12-935_zpsda2ea906.jpg

alternator off to get sorted, few more bits & pieces to do in the front aswell & to get the thermostat out
http://i872.photobucket.com/albums/ab288/nosmokenopoke/Shanes%20E36%20323i/2013-04-13-936_zpsd51fb212.jpg
drilled 4 holes in the thermostat on eoinK's reccomendation.. will drill more if it continues to heat while drivin the bag out of it on the slab
http://i872.photobucket.com/albums/ab288/nosmokenopoke/Shanes%20E36%20323i/2013-04-13-939_zps7ccb33de.jpg

clutch is slippin like fuck, so ordering a ceramic disc for it now too, along with 3 sets of coilovers for the tds, this yolk & another e36 this week.. 195 delivered for JOM bluelines is not bad atall :D

[TorqueWorks]

Right Update time
Firstly.. Crankshaft seal pouring oil.. did the sump seal & crank seal twice since & both times leaks.. absolute torture! Still leaking all over the clutch so no 3rd yet again on sunday
sump down & cleaned
http://i872.photobucket.com/albums/ab288/nosmokenopoke/P1010667_zps76381310.jpg
Engine had to be lifted a few inches to take the sump out
http://i872.photobucket.com/albums/ab288/nosmokenopoke/P1010671_zps441f13ae.jpg

Thanks Mr. Postman.. Coilovers :D fitted them, and the rear trailing arm bushings the night before... LastMinute much, got sets for shanes petrol yolk aswell as eoink, and a few paddle clutches for shane, eoin & another lad aswell..
http://i872.photobucket.com/albums/ab288/nosmokenopoke/P1010672_zps87dfb4fa.jpg

Anyways: DriftFest Tynagh 19/5/13
First lap out on track and no power pouring smoke & lagging very bad even with the chip off, only boosting 0.4 bar and then kept tripping into limp mode.. but would spool fine until under pressure, decided it was an air restriction so we pulled out the air filter, dropped it on the bonnet & a good cupfull of sand scattered out of it, as well as being choked with oil... straight away the difference was noticable in power..
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-05-20-001_zpsebe1dedb.jpg
Next round out on track was full power through the first bit of the turn, but kicked into limp mode at the end of the turn... opened the bonnet to find exhaust gasses bellowing out from the exhaust manifold where the EGR connects on, just before the turbo.. ofcourse our cold air intake was left at home by accident so only thing for it was take off the bonnet so it wouldnt be sucking in ehxaust gasses.. and straight away LOTS more power, altho she was down to 1.3 bar boost due to the exhaust pressure dropping.. Unfortunately it was lunchtime before we got full power back into the car, but made for a great afternoon blackening the track
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-05-20-004_zpsddd07674.jpg
daniel got a few stickers made up
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-05-20-003_zps77198d19.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-05-20-002_zps85dd1c37.jpg


And most importantly a short one lap onboard video in HD :D Full Of The Pipe
BMW 325TDS Diesel Drifting at DriftFest Tynagh 2013 - YouTube (http://www.youtube.com/watch?v=5r6UI9dNxQc)

http://www.youtube.com/watch?v=5r6UI9dNxQc

[TorqueWorks]

Bit of pollution here, this was before we took off the bonnet so it wasnt getting enough air & just bellowing smoke
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-snc6/9878_199472503510280_424915709_n.jpg

Car doesnt have to be in the picture to know where we just were
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-frc3/389414_572115766155895_838645578_n.jpg

and daniel just doing a bit of landscaping, front lip is not a land leveller
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-prn1/603757_572117232822415_1586175058_n.jpg

Shes sitting an awful lot more stable with the coilovers
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-ash3/941356_480062278732751_782194807_n.jpg

bonnet off & it was able to get that air it needed so less smoke
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-ash3/168240_480064742065838_274120490_n.jpg
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-ash4/481803_480064692065843_1459848651_n.jpg
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash3/947015_459870957440053_690230249_n.jpg

[TorqueWorks]

But it looks like seats in the back in photos lol

the headrests may be built into the surround over the back window cant remember



anyways, the reason we had to take off the bonnet.. fuckin EGR
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-05-25-015_zpsf883c314.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-05-25-016_zps764b7fe7.jpg

so much to do now Im just going lifting the engine out to fuck altogether
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-05-25-005_zps4ac4b50b.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-05-25-017_zps12c78741.jpg

and shanes car is coming along well, sitting on coilovers... Altho the 4.8L 400HP Porsche Cayenne S kinda makes our bmw's feel like we're on a slow drive to mass
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-05-25-006_zpsebcf6fcf.jpg

[TorqueWorks]

Bit of an update before tynagh... Getting there slowly hopefully in a better place than we were last time round

Anyways Engine out
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-06-04-042_zpscc967aaa.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-06-04-044_zps7ce7d5c1.jpg
hollow looking filthy engine bay
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-06-04-045_zps31bd0b6d.jpg
Engine Upside down for working on
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-06-13-053_zpscc285255.jpg
EGR port welded solid
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-06-12-049_zps04a21763.jpg
new housing for the crank shaft seal along with New Genuine BMW gasket
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-06-13-050_zps8dbe84b9.jpg

where its been causing me the hassle, along that joint
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-06-13-051_zps2d2cfa15.jpg
Sump Gasket, Genuine BMW brand new.. a very dear piece but looks like it will work
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-06-13-052_zps98ab46c1.jpg
bit of gasket sealer just to help on the outside
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-06-13-054_zpseccd3075.jpg

back together at last, torqued to the limit, feels much better than before aswell
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-06-13-056_zps17b37bc1.jpg
making a quick release harness for the engine loom.. no doubt the engine will be out again
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-06-14-062_zps7a389bce.jpg

labels added to the on/off switch for the Chip :D Just incase eratic idling and Black Smoke wasnt enough
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-06-13-059_zpsf1e027cc.jpg


Engine back in now in the morning

[TorqueWorks]

shaun Okeefes old 323 engine with a fucked headgakset that we robbed the crank seal housing from..
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-06-16-074_zps446648c1.jpg
only thing I could find the right size to press out the crank seal without damaging it, 110mm piston from a Deutz engine

also got this from shauns old 323, M Sport anti roll bar, 1.5mm thicker than original but fuck it tis an improvement on the job.. thanks Mossy
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-06-15-064_zps0434ea45.jpg




Eoin & Ashley dropped out saturday afternoon for the look, we pulled the car out and powerwashed the engine bay
just before it went out, still filthy
http://i1143.photobucket.com/albums/n627/Owly-11859/trd042_zps99cb07bc.jpg
much cleaner engine bay later and with the help of Eoin & Ashley again we had the engine back in in an hour... Huge thanks to them they really sped up the job for us
http://i1143.photobucket.com/albums/n627/Owly-11859/trd047_zpsa162dc79.jpg
few hours later everything on bar the bumpers and few bits
http://i1143.photobucket.com/albums/n627/Owly-11859/trd048_zps9d6f4a5b.jpg


Got the wiring loom sorted with connectors including the high frequency shielded signal wires to the pump that had to be shielded with aluminium tape
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-06-15-065_zpsd008d053.jpg
and connected
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-06-16-070_zps84d4efa6.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-06-16-069_zps78f3d81f.jpg



so anyways we made it to tynagh
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-06-16-066_zpsec33d6bd.jpg


first go round the track she blew the welded blank in the exhaust, we welded onto a pressed in ring, luckily Owly took a notion to weld the Air intake side the night before and that fitted fairly well altho there was a bit of a blow causing us a few heat soak issues, induction kit we stuck on was too restrictive aswell, so when we half disconnected it beside the turbo it was sucking in the hot air around the exhaust.. Next time were making our own air filter with little to no restriction
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-06-16-067_zps01169331.jpg


burned over 50 litres of diesel got an absolute savage amount of tracktime with the open pit afternoon, ran out of diesel at 4 just as things started getting damp :(
But mainly, the best part of it was NO MORE OIL LEAKS :D genuine OEM gaskets FTW pulling in 3rd like a train now, so gotta say Im Delighted with that.. Finally get to concentrate on other stuff for the next day, which doesnt sound like it will be for a while.... Superdrift is well worth the money way more tracktime than the last crowd, altho I think they're gone completely now

Il post up pics and vids of how it ran on sunday over the next few days now

[TorqueWorks]

Right, back on this again since there hasnt been a drift day in months, Anyways after impatiently waiting we are booked in for Tynagh SuperDrift on the 22nd of september :D, thanks EoinK

A few weeks back we decided to weigh everything, and somehow forgot to weigh shanes 323i coupe which was the one we wanted to compare with..

got the weight scales setup outside the shed
first up was the TDS
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-07-25-182_zps360de75a.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-07-25-183_zps21a73ec6.jpg

then shanes GTTDI Golf & quite a lot of tools in the boot & back seat weighed in at 1375kg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-07-25-184_zps74a69f4a.jpg

My 320d weighed in at 1460kg with not a lot in it
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-07-25-186_zps517fbf37.jpg

and ofcourse the fendt just under 10 tonne
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-07-25-188_zpsbf72fbaa.jpg


new shiny strutbrace :D to what purpose it serves on a flat track I dont know but it will be handy for when the bonnet is off on a sunny day in tynagh, would've been daecent the last two times sitting up on the windscreen
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-08-24-241_zps0950ff81.jpg

removed the sunroof to make the rollcage fit better, saved 5kg at best :/ and have to get a seal for it now as the old one was fucked anyways, but tis worse now that we pulled it off altogether
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-08-24-244_zpsbd60f085.jpg
sprung hinges
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-08-24-242_zps4f392120.jpg
Bit of wiring to remove now too
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-08-24-243_zpsd0822017.jpg


Rollcage ready to go in after a few slight modifications since we were at it last
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-08-25-247_zps19e504ea.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-08-25-246_zpsb1f7c0a8.jpg


and I finally got round to getting the E36 diagnostics cable
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-07-17-144_zpse6918a43.jpg

And And And I got around to getting a vid up of the last day in Tynagh, showing a slight improvement in sliding the straights with 3rd gear :D Only getting used of the higher speed now and getting the hang of it a bit more, hopefully the next day we will have a less restrictive air filter and no heat soak so give us a bit more to throw out in 3rd all the same
BMW 325TDS Diesel Drifting SuperDrift 16th June Tynagh - YouTube (http://www.youtube.com/watch?v=7RKGl6iBPXk)

http://www.youtube.com/watch?v=7RKGl6iBPXk

[TorqueWorks]

Right so update as far as thismorning

we aquired a pair of these a week or so back, one bigger than the other. This is the heavy one which EoinK now has
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-09-02-253_zps7b92616f.jpg

we also came up with a plan for the restrictive air filter issue we've been having
old sponge filter done away with
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-09-02-249_zpsb9dc12b2.jpg
and a very very tough set of bright red tights pulled over the cone, looks savage and has absolutely Zero restriction.
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-09-02-252_zps54bbb604.jpg



took a spin to Cork saturday picked up a few bits & pieces, thanks to EoinK for bringing the van, wouldnt have managed to fit it all in the car

6 tarmac tyres
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-09-08-264_zps9f617010.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-09-08-269_zps7c1ba432.jpg

and threw them on thismorning, did the front brake pads while we were at it
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-09-08-273_zps2f9aa39b.jpg

and did a set for shane aswell
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-09-08-274_zpsd6d45bb2.jpg

a pair of harnesses
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-09-08-267_zpsa838b1a1.jpg

and an out of date OMP Seat thats just a bit too small for me unfortunately.. so thats FOR SALEand have a willians harness to sell aswell
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-09-08-266_zps72e61b08.jpg


went a little bit mental & ended up buying these lastnight, FIA approved & still in date for another year and a few months :P
They fit me like a glove, Owly is comfortable in them too so all is good. Wicked comfortable I gotta say
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-09-08-263_zps87daa60a.jpg



good bit done today now but didnt get pics.. will get them over the coming days now

[TorqueWorks]

Right, given the seats we now had to adapt the driving seat to be able to move up/down and in/out to suit Owlys height difference over mine. Used the base of a Grammer tractor seat to be able to use the movements and mounted it backways because the handle for forward/back would catch the exhaust otherwise
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-09-13-276_zps2cab326b.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-09-14-279_zpse50f4279.jpg
down to the last
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-09-13-278_zps308a711f.jpg
up to the last
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-09-13-277_zps515efa03.jpg

then a bit of cage
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-09-14-284_zps119bd763.jpg
mikes vertical welding is somethig else
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-09-14-286_zps65d4fae4.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-09-14-287_zpsd414841c.jpg
even had to unbolt the back doors to get mike in to the aquard ones
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-09-15-305_zps0f454540.jpg

and attempt 2 at the exhaust manifold after the press in ring blew out the last day in tynagh
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-09-15-289_zps1cdb43c8.jpg


and done
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-09-15-307_zps41a3f7db.jpg

then shane broke in with his petrol..... before he was fucked back out the door with it & made leave it outside, caged ready to go for tynagh too :D

http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-09-13-275_zps99c5ebaa.jpg
small bit more tidying nextweek, throw in the harnesses and the new Hyd Handbrake and all should be good.. Bring on Tynagh

Happy Sideways
:D

[TorqueWorks]

RIght, Update time after Tynagh, shane couldnt make it... Again! so his was left at home

our car
Managed to get 4 laps in :(

First lap
First out in the morning it was a case of "HOLY FUCK" this is Waaaaaaay more powerful than ever, this is due to the exhaust manifold not leaking anymore, the new air filter we made up with pretty much Zero Restriction, and the bit of extra tweaking I did on the diesel pump and boost pressure on the car friday & saturday

2nd lap:
Driveshaft carrier bushing gave up, bearing still good
http://i872.photobucket.com/albums/ab288/nosmokenopoke/2013-09-22-319_1_zpsb62c3a07.jpg


10am a hard drive home, pulled in the 328i 4door and pulled the driveshaft out of it (same part number carrier as the tds, same prop aswell).. Back to tynagh at 1:30, threw it in and back out for another 2 laps at 2pm, exact repeat of first thing in the morning, a second one tore out of the car. Both times it was the top corner when it got 3rd gear it went pop

as the afternoon tore on and eoinK trying to burn off what tyres we had with us, tragedy struck his 328i as a skyline sideswiped the car
the coilover took most of the impact, along with a bent steering colum, and a broken engine mount
http://i872.photobucket.com/albums/ab288/nosmokenopoke/2013-09-22-321_1_zps06b0816f.jpg
our car got robbed trying to get the 328i back out
http://i872.photobucket.com/albums/ab288/nosmokenopoke/2013-09-22-320_zps08c15480.jpg

the skyline burst its intercooler and he cut the exhaust off his van and put a piece in instead of the intercooler just to keep going, meanwhile Mikey's sierra wasnt going well either and had to retire..

[TorqueWorks]

Right need advice

need to know about the prop carrier in an M3, its the same bearing but different carrier. and I believe a Ford Transit has a 30mm inside diameter bearing aswell in some of them.. Id say thats a heavier carrier than even the M3

also, while we're having issues on the drivetrain, thinking about machining up a steel piece instead of the rubber coupling yolk that bolts onto the back of the gearbox and the prop bolts to it, anyone any experience with any of those?

Probably a good Idea to get the PropShaft Balanced again??

[mayo s14]

some amount of effort gone into this .. would ya not just bite the bullet an fuck m3 running gear into it and be done ??

[TorqueWorks]

some amount of effort gone into this .. would ya not just bite the bullet an fuck m3 running gear into it and be done ??

Not sure whether you meen, engine & all is it or what? That defeats the purpose and besides we have a 328i aswell and the TDS is more craic

Running gear wont work for various reasons, gearbox... apparently unbreakable ZF box :D, propshaft is the same as 328i 4door, Id need an M3 4door prop to get a different prop and its pretty much the same thing just with an extra CV joint on the diff

Driveshafts to the wheels are heavier than M3 I believe, , diff ratios different & no good to us

diesel flywheel is pretty much the same as the 323i 325i petrols (328i is bigger diameter again) but the difference is theres dowels on the back of flywheel for RPM sensor where the petrols measure RPM on the front of the engine.. If we were stuck we could machine dowels into a petrol flywheel

[kouki_kid]

I fitted an alloy gearbox coupler to mick barrys m3 compact and it destroyed gearboxes in no time just rattled them to pieces so deffo use a rubber coupler,if the gubbo on the box is worn it will destroy centre bearings so just put new gubbo on the box and a good balanced prop with good centre bearing!!

[TorqueWorks]

I fitted an alloy gearbox coupler to mick barrys m3 compact and it destroyed gearboxes in no time just rattled them to pieces so deffo use a rubber coupler,if the gubbo on the box is worn it will destroy centre bearings so just put new gubbo on the box and a good balanced prop with good centre bearing!!

thanks man good reply
next question, suppose I may ask in terms of petrol cars

will an M3 guibo fit a 328i, the 328i is the same as mine and I believe the M3 Guibo would be beefier and seems to be the same bolt pattern, both are 96MM/12 but different part numbers

wheres the best place to get the shafts balanced propperly?

[mike e30]

A 328is and an 3.0 m3 both use the zf box so i would imagine there the same

[TorqueWorks]

A 328is and an 3.0 m3 both use the zf box so i would imagine there the same

the guibo is a different part number anyways I can tell ya that, but seems to be the same size. the M3 is Just stiffer Im guessing

M3 evo and M3 are the same part

[mike e30]

You could prob get some kinda polly bush version on ebay or someplace on line

[Smokey Bear]

thanks man good reply
next question, suppose I may ask in terms of petrol cars

will an M3 guibo fit a 328i, the 328i is the same as mine and I believe the M3 Guibo would be beefier and seems to be the same bolt pattern, both are 96MM/12 but different part numbers

wheres the best place to get the shafts balanced propperly?

Heard of a place called shaft tec I think they do farm stuff and all that Craic.

I'll measure a 530d guibo if you like against the m3 one, I have a feeling it's bigger. That could sort you out!

The other thing is if your wrecking guibo a and centre bearings then your engine mounts are probably worn to fuck. If your changing them check your subframe, my subframe was cracked and ripped in the m3 around the mounts and I had to put plates on it.

[mantahead]

keep up the black reek.

was wondering what rubber couplers to use myself as i need to make a shaft from 330d gearbox to supra backend.

what bout this kinda thing.
http://thumbs1.ebaystatic.com/d/l225/m/mRVBmcnUo6wg-WW7fRuFP9A.jpg

[mantahead]

I fitted an alloy gearbox coupler to mick barrys m3 compact and it destroyed gearboxes in no time just rattled them to pieces so deffo use a rubber coupler,if the gubbo on the box is worn it will destroy centre bearings so just put new gubbo on the box and a good balanced prop with good centre bearing!!

hi, was thinking of alloy coupler myself, not being smart but was coupler properly made, was it done on dividing head pcd? any pics?

i don't want gearbox trouble after the bother i have went to,
just curious, was it 2 piece driveshaft?

thanks.

[TorqueWorks]

hi, was thinking of alloy coupler myself, not being smart but was coupler properly made, was it done on dividing head pcd? any pics?

i don't want gearbox trouble after the bother i have went to,
just curious, was it 2 piece driveshaft?

thanks.

Right, Ive been looking up about fully poly couplers but they're supposed to be fairly shite the first crack appears they discentegrate, altho that semi solid one looks like it would be daecent enough, and I read a few more places agreeing that a fully solid one is a definite NO

thinking as suggested to solid up the engine mounts. the ones in it are pretty much brand new but theres still quite a lot of flex there when shes going hard, gearbox mounts same treatment harden her up

subframe is ok no damage there, diff & all that back end is solid as fuck too so thats all good

[mantahead]

right enough, sure there is no universal joint in ends of shaft, see the corvette boys have trouble as well.
https://www.google.co.uk/url?sa=t&rct=j&q=&esrc=s&source=web&cd=5&cad=rja&ved=0CFIQFjAE&url=http%3A%2F%2Fwww.ls1gto.com%2Fforums%2Fshowthr ead.php%3Ft%3D344952&ei=wGVDUuvdNMev0QXIsYEo&usg=AFQjCNF_arV222j0zNmsR48om-vLQ0qZyw&sig2=UysobillDf1W2MggKYcVoA

[kouki_kid]

hi, was thinking of alloy coupler myself, not being smart but was coupler properly made, was it done on dividing head pcd? any pics?

i don't want gearbox trouble after the bother i have went to,
just curious, was it 2 piece driveshaft?

thanks.

Was made by an engineering lecturer in a local collage was 100% right never damaged a centre bearing just rattled boxes very quickly I don't have a pic was on car wen it was sold and never seen it again after!

[TorqueWorks]

the machined aluminium piece them boys were onabout I've been looking into a lot, think Im going to go down that route now after looking at the Guibo in the car today

Found this by RevShift
https://www.revshift.com/shop/drivetrain/bmw-flex-disc-large-lk-96mm/12mm-.php
https://www.revshift.com/shop/images/source/9612disc.jpg

Semi Solid, Heres what the feedback I've got on it so far, wading through the bullshit..

-A fully solid one is not an option its too solid, this semi solid piece is the step up from stock

- Removes gear slop (I have noticed this)

-with this piece the gearbox flanges has to be aligned precisely with the diff flanges, as the rubber guibo used to take the tolerence of a few degrees, with the new piece you're right down to about 1-2 degrees of alignment from parallel. Tis might require shimming the gearbox mounts ect to get alignment perfect, also meens Im going to go with the Revshift Poly Engine Mounts and Gearbox mounts to solid it all up
http://mbworld.org/forums/attachments/c-class-w203/217699d1315484821-knocking-rear-high-revs-pinion-angle.jpg

anyways this is the underneath of the car after 4 laps, Guibo torn to shite.. the cause of the carrier bushing failure
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-10-05-333_zps6b5f8d8f.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-10-05-335_zps0aa919bd.jpg
and what it did to the carrier
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-10-05-336_zps29fc6aca.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/2013-10-05-337_zps699bad12.jpg

[mike e30]

After lookin at this mine is so goin to go in absulute shite i made the prop my self in my v8 e30. And iav seen already with the new touring shell for some reason the prick isnt sitting exact with the output shaft of the back o the gearbox dont no whats causing it as it was fine in the coupe

[TorqueWorks]

After lookin at this mine is so goin to go in absulute shite i made the prop my self in my v8 e30. And iav seen already with the new touring shell for some reason the prick isnt sitting exact with the output shaft of the back o the gearbox dont no whats causing it as it was fine in the coupe

In the E36's the M3's could handle the intolerence in the drives without vibrations as they have a CV joint on the diff side rather than the universal joints in all the other models..

my revshift stuff is finally through customs & now with An Post.. May not have to turn down the power for sunday afterall :D which meens I have the great pleasure of having to go aligning at the weekend now before tynagh

picked up this handy gadget for aligning the drives
https://scontent-b-ams.xx.fbcdn.net/hphotos-ash3/1395165_10202006763044292_1206842761_n.jpg

[Chuck_g]

Why not loose the carrier bearing all together and have a solid prop? Would work a treat!!

Ps, seen this around Tynagh, some job :)

[TorqueWorks]

Why not loose the carrier bearing all together and have a solid prop? Would work a treat!!

Ps, seen this around Tynagh, some job :)

Ah if this works there should be no movement or vibrations to cause the carrier to be under any sort of pressure

Ha thanks, Dont think our driver ability is quite up to standard yet to really show what it can do..Still only learning

[TorqueWorks]

Revshift bits finally came
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20131115_1117091_zps1ae6f84c.jpg

Started at it then after the pollution went away
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20131115_1828441_zps46f557ee.jpg

then a look at the Guibo / Flex Disc... old vs new
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20131115_1951261_zps7c355269.jpg


With the rear of the car lifted the Diff is 4.5 degrees off vertical tilting down, while the gearbox only was 1 degree tilting up.. difference 3.5 & needs to be under 1 degree, shimming the diff carrier to reduce that angle
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20131115_1954491_zpsac172f36.jpg

[pmcn2010]

class

[TorqueWorks]

new engine & gearbox mounts fitted & alignment done by shimming the diff carrier with 4 washers above the rear bolts.

Revshift coupler fitted along with a fully balanced propshaft
http://i872.photobucket.com/albums/ab288/nosmokenopoke/20131116_134903_zps0c034241.jpg

ready for tynagh
http://i872.photobucket.com/albums/ab288/nosmokenopoke/20131116_213118_zpsa981d367.jpg


then tynagh, turned her down a good bit on the day to get a bit less sensitive throttle and less torque rather than the more on/off way it was set for on the previous dry day as it had been turned up so much
https://scontent-b-ams.xx.fbcdn.net/hphotos-prn2/1461205_563105580428420_1423005053_n.jpg
https://scontent-b-ams.xx.fbcdn.net/hphotos-prn2/1422625_640463855973874_648559060_n.jpg
https://scontent-a-ams.xx.fbcdn.net/hphotos-ash3/1463035_638353196184940_322706394_n.jpg
https://scontent-a-ams.xx.fbcdn.net/hphotos-prn2/1454846_509585159149047_1213670982_n.jpg


So after the day and from our bit of a roadtest saturday I can say there were absolutely no extra vibrations up through the gearstick while its driving.. if anything theres less..
the gear changes felt much more solid and less slop which was nice..
the engine mounts are veeeeeeery hard indeed and theres absolutely no engine flex any more which is also good


I also have noticed a bit of a flutter in the top end of the revs every now & then when the car is cold, where its like the car starts to only run on only 3 or 4 cylinders
after much deliberation & figuring out its as if there is an injector or two sticking open at the high revs & not atomising the diesel atall, but pouring it into the cylinders instead...
Next step in the coming weeks is to take the injectors out & test them all, both pressure test & leak test them

[Eoin k]

some man for the work Kev. I'll buzz ya over the week-end.

[Duck Drift]

Is your flutter when giving her a high rev in first or no load cause mine
Dose the same when I put the boost over 1.5 bar or slightly less
Think it's some kind of boost cut and she fires a heap of fuel in, takes a few seconds to clear runs like shite and loads a smoke

[TorqueWorks]

both no load and load... but only when its cold.. once the car gets up to temp its grand never happens

but yes it does do exactly that spluttering & choking & bellowing smoke, but sometimes it can go 5 minutes before it clears.. turning off the car for about 30 seconds normally cures it

I dont think so much its a boost cut as the pressure sensor is fucked and not connected half the time.. nearly certain its not an ECU thing it feels more like its purely mechanical

[Duck Drift]

Sounds like what's mine dose it might last longer but I do
Kinda rev it out, may be due to the raised fuel pressure of the map I have
And the ecu with a slight software flaw, I've had a few 325tds and they all
Did it slightly but remapping seems to exaggerate it

[TorqueWorks]

Sounds like what's mine dose it might last longer but I do
Kinda rev it out, may be due to the raised fuel pressure of the map I have
And the ecu with a slight software flaw, I've had a few 325tds and they all
Did it slightly but remapping seems to exaggerate it

Ah this is only becoming noticable after the last drift day.. its when its between 5000 and 6000 revs that mine starts giving bother now where it usent before.. when its a bit hotter then it doesnt happen.I think the diesel then is more viscous and goes up around the needle in the injector more freely and the needle is able to spring back easier then

[mantahead]

mechanical pump required :tongue:

there is a guy somewhere that fitted a mercedes m pump to 325tds

[TorqueWorks]

mechanical pump required :tongue:

there is a guy somewhere that fitted a mercedes m pump to 325tds

not nececarily, it would be handy alright and lovely to have an inline pump...

there is an easier choice of mechanical pump from a 524td... but none the less the only thing different between the mechanical and electrical is how the governor is opened.. the actual working mechanics of the thing are the same and completely interchangable..

will be going for 12mm plunger & that can be got from any sort of tractor or truck with a bosch rotary pump.. and a higher lift cam plate from an Iveco cos they have one of the highest lift.. more push more diesel :) that all requires a MLS headgasket and a turbo aswell.. a while off that stage yet the bank account is looking shook still in college

A bit more fancy control of the chip wouldnt go astray, maybe linearly changing with the accelerator position would be very nice :) might concider working on that after exams in january if I sort out this top end spluttering... oh and an electronic timing advance aswell :D

[mantahead]

hi,
i built both electronic and mechanical pumps for the merc and was tortured a bit with limp modes and rpm issues on the electronic pump.
then i got Dieselmeken in Sweden to set the mechanical pump up, problem sorted.
although it would be nice to have the money to go standalone ecu with electronic pump and have a nice quick rev limiter.

[TorqueWorks]

hi,
i built both electronic and mechanical pumps for the merc and was tortured a bit with limp modes and rpm issues on the electronic pump.
then i got Dieselmeken in Sweden to set the mechanical pump up, problem sorted.
although it would be nice to have the money to go standalone ecu with electronic pump and have a nice quick rev limiter.


no limp mode issues for me strangely.. RPM issues I think are purely mechanical problems with this too.. Long term plan is to go & make an ecu with an arduino or something like that, I've another engine there to be doing a bit of R&D with :P


anyways, took the injectors out yesterday.. had to make a socket to go down over them.. crude but it worked :D
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20131208_1854251_zps76150486.jpg


injector itself
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20131208_1830262_zpsa18fa0cf.jpg

then stuck them all on this old toy.. Genuine Bosch injector tester from back in the day
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20131208_1830431_zpsbdb9968f.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20131208_1830541_zps7ea91e5a.jpg

http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20131208_1831061_zpsa262c40e.jpg


what I discovered, the injector in Cyl 1 was slightly different to the others, not leaking as such.. but the spray pattern was more focused, and the opening pressure was odd it partially opened & squirted a tiny jet unlike the other 5 which chuffed mist when touching off the opening pressure

change that now & pull out the injector from another car instead. see what happens at 6000rpm with that changed, could make all the difference.. If not, start looking at my pre pump

[LarZ]

Arduino ECU... EPIC...

[TorqueWorks]

started looking into water/meth injection heavily a few weeks ago & I've decided its worth a shot..

anybody know about it?



Take a read of this:
http://www.dieselpowermag.com/tech/1005dp_water_methanol_injection_how_much_is_too_mu ch/






Why Im so interested in it is huge Horsepower & Torque gains without raising the compression ratio that much, and it lowers EGT's.... which is something I've been a little concerned about with this engine as they Reeeeeeeeeealy dont like getting too hot, hence the shorter exhaust.. and it basically steam cleans the engine...which is quite carboned up by the looks of taking out the injectors


***If you have no interest in water/meth injection, microcontrollers & how to DIY it stop reading now****


the water basically absorbs some of the heat of combustion which is only a short duration in the power stroke.. then the water turns to steam for the rest of the power stroke.. steam expands quite a lot & thats how steam engines work..

The cheaper kits are using a simple boost pressure relay that turns on the pump when the pressure reaches the set pressure. the kit starts injection at 100%

the more advanced ones are using a pressure sensor and controlling the pump to inject between about 60% and 100% as the pressure rises or rpm rises, depending on the kit.. this maximises the power gains from the water/meth injection

the prices of these kits are feckin mad altogether even for the basic pressure relay

Since the control can be so basic I've decided to develop my own, as theres other advantages to making my own controller. One of the main reasons I want to do this is the diesel pump has a 5 degree timing advance solenoid :D

one of the side effects of water/meth injection is a slight lag in combustion, something the timing advance solenoid can counteract :D be like Vaaaaaaaaaatec kicking in, except actually developing POWER not noise like hondas seem to do.

so... what do I need:

a Water/meth pump, something like this, the pressure can be adjusted down if needs be.. possibly the biggest expense of the whole job at around 100 quid
http://www.alcohol-injection.com/en/pumps/281-300-psi-recirculation-pump.html
http://www.alcohol-injection.com/427-thickbox_default/300-psi-recirculation-pump.jpg

injector nozzles, 10E each
this sort from McMaster-Carr, not exactly sure which to go for so probably end up getting both & starting small, working up. both full cone 80 degree spray patterns.. model numbers 3178k46 and 3178k47
http://www.mcmaster.com/#catalog/119/2074/=pw7b5g
http://www.alkymethinjection.com/images/used/nozzle2.gif


boost pressure sensor, I got one for 0 to 2.5 Bar with a 0 to 5V output as its sensetive enough for what I need and it future proofs it for when we get a larger turbo
the one I chose was an MPX4250AP sensor
http://i.ebayimg.com/00/s/NTIzWDU1Nw==/z/34oAAOxy9bxRz4VZ/$T2eC16ZHJGMFFo)j9Jn7BRz4VYvl1Q~~60_12.JPG


optional extra: a 300psi solenoid valve to place right beside the injection nossle so it doesnt injest water when it doesnt need to
something like this, altho more of a concern for petrol cars not exactly nececary on the diesel.. Il see!
they come in 12v too, about 40 quid
http://www.newark.com/gems-sensors/a2013-v-vo-c203/solenoid-valve/dp/45M6099
http://www.newark.com/productimages/standard/en_US/4317824.jpg


then a H bridge motor controller to be able to control the voltage to the pump from about 6ish volts to full voltage of the car, 14.4V and able to handle 10A + current draw to the pump. This is the way of controlling the quantity of water injected using PWM from a microcontroller as the boost pressure & RPM's rise
one I have can handle 30A
http://i.ebayimg.com/t/30A-Single-H-Bridge-Motor-Driver-Module-PID-for-Arduino-Intelligent-Car-/00/s/NjAwWDYwMA==/z/eCMAAOxyPLpRfNHA/$(KGrHqRHJFUFEMBdpdViBRfNG+zKf!~~60_3.JPG



and... the microcontroller I've started playing with, an Arduino UNO R3.
all I've being doing so far is pricking with the PWM outputs changing an LED intensity, just messing really
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20131220_2017561_zpsf3c684b5.jpg

I also picked up a 4 line LCD display just to make the job look fancy
http://i.ebayimg.com/t/IIC-I2C-TWI-SP-I-Serial-Interface2004-20X4-Character-LCD-Module-Display-Blue-/00/s/NTAwWDUwMA==/z/1lIAAOxyYI9Rxu1P/$(KGrHqZHJEEFGvim4EYRBR)u1PQf7g~~60_12.JPG

and something for another thing Ive wanted to do for a while, be able to see whats happeningwith the car from the side of the track on the laptop. plan to send stuff like engine RPM, boost pressure, throttle position, diesel tank level and water/meth injection quantity.
I have these transmitters capable of broadcasting 1km
http://www.dfrobot.com/index.php?route=product/product&product_id=57#.UrTQd4XvjKo
http://www.dfrobot.com/image/cache/data/TEL0005/TEL0005-2-340x340.jpg

theres also one other thing I can do with the microcontroller, I can make the chip I have a lot more intelligent and progressive the more the accelerator pedal is pressed

[Sean180sx]

Great read up . Keep up the good work interests me this kinda stuff

[TorqueWorks]

right well we took apart the bad injector for the laugh, incredible the amount of sludge type dirt inside the injector itself, when we cleaed it & put it back together it still wasnt right, the needle or the nozzle obviously damaged
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20131224_1412151_zpsa3a8c014.jpg

took another injector from another M51 engine I've lying around, tested it & it looked good so put all the good injectors in & tried it out We're back to 6k revs again :D
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/1545158_10202373297727430_29872776_n_zps116fd291.j pg


something else I've been working on, the Live digital dash on LabView, receiving & displaying information on the laptop directly from the Arduino as if it was a com port, basically the same program that will be used with the transmitters.. Il be testing them in late january when Ive a week off.
Not bad for one day playing around with labview and the arduino
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/BMWDigitalDashLabview_zps91ecad3e.jpg

[TorqueWorks]

All the bits for Water/Meth injection and the remote digital dash arrived
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140118_103732_zpsa0623da4.jpg

The idea, EGR valve not working anymore, lovely spot to put an injector
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140120_181244_zps450a8fa2.jpg

made it happen
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140124_213836_zpse5f79066.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140124_213926_zpsfd99cec8.jpg

http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140124_214007_zps1074d8a2.jpg

hooked it all up & checked out the spray angle, and decided I'd be able to pull back the nozzle 10mm to get a better spread of spray throughout the intake, so I machined that off the injector side
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140203_233616_zps882e2e7d.jpg

Dont think Im going to have time to get this running for tynagh in march, too busy on another project at the min unfortunately, but it ties up with this which is handy :D

[TorqueWorks]

Update: whats been done since
New thermostat fitted, 93 degree one.. probably should be the 88 degree but ah fuckit tis alright at this stage
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140215_234404_zps098c4c84.jpg

power steering pump swapped out from another tds I picked up for bits, new propshaft carrier fitted, & the cooling system bled propperly.... hence the angle its jacked to
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140215_234422_zpsfcf7afd7.jpg


Methanol injector fitted back onto the air intake
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140216_002351_zpsacabb299.jpg

skimmed the rear discs & bled the hydraulic handbrake & got another bubble of air out... something still odd about it tho, locks up fine even on the tarmac but it doesnt spring back like its meant to :confused: press the brake & that pushes it back alright
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140301_155843_zps1cd01a1c.jpg

then went working on a few bits, figuring out the throttle position sensor & the timing advance solenoid
what 12V PWM to that solenoid looks like with the engine on tickover.. timing is just little under half advanced, and as you rev up the timing retracts a little..Ima have to start recording that
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140222_130558_zpsb438c945.jpg

then, thisevening I picked up 20L of methanol
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140305_222115_zps2d864558.jpg
to pasify my mind that it was infact methanol I lit a drop.. it is :D
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140305_221812_zpsa4efc6da.jpg


Might throw it into a Mass Spec in college to check its purity... but either way the meth injection wont be up & running for SuperDrift this Sunday.


I discovered my power limitation currently is how much air the turbo can give.. The pump can deliver more than enough diesel than the engine can burn at the min, so...Bigger turbo mission coming up...

With the turbo change I'm going in a slightly unusual direction with it, Variable geometry turbo, it will spool a lot faster and can deliver max boost longer than a conventional wastegate. probably off an E46 330d, and to control it with an arduino... funny enough I found a guy who done it already & has a full system developed for live mapping & everything for it, master work I have to say

[mike e30]

Have u looked into fitting a mechanical pump onto one of these iam starting a conversion next month with one of these engines into a old w123 merc and figured a mechanical pump would make it a lot more straight forward

[TorqueWorks]

Have u looked into fitting a mechanical pump onto one of these iam starting a conversion next month with one of these engines into a old w123 merc and figured a mechanical pump would make it a lot more straight forward

Considered it & decided NO, shur theres no craic in that atall, mechanical pump is the easy way out.. since Its eletrical engineering Im doing figuring them out is a bit more of a challenge, the pump & controls in these engines kinda make sense to me since I've been looking at them so long at this stage

[mike e30]

In that case how would u feel about wiring one into a merc :-)

[TorqueWorks]

In that case how would u feel about wiring one into a merc :-)

let me do my own first then try yours :P unless you want to take a leap of faith... On another project until june so I wont have time till then to even go at the bmw propperly

[mike e30]

Ara ial work it someway was looking at the loom last night and its all fairly straight forward there only seems to be like 6 wires connected to the potentiometor so it couldnt be to bad

[TorqueWorks]

Ara ial work it someway was looking at the loom last night and its all fairly straight forward there only seems to be like 6 wires connected to the potentiometor so it couldnt be to bad
Is that the throttle youre onabout or the pump?

[mike e30]

Trottle but a mecanical pump would sort all that gayness out

[DaveM-sport]

VGT will make a nice difference. I fitted one to my Defender and it has almost instant power from pretty much idle unlike before where you had to get it wound up to about 2000 before it really got going.

[TorqueWorks]

VGT will make a nice difference. I fitted one to my Defender and it has almost instant power from pretty much idle unlike before where you had to get it wound up to about 2000 before it really got going.

You do the mechanical control way or make an ecu or how?

[TorqueWorks]

Update time.. Tynagh was wet once again had to turn the power right down..

Running the track in reverse presented an interesting challenge, Began using the hydraulic handbrake for the first time and started getting the hang of clipping points too :D

spent quite a long time in tynagh that week, with a half day karting there on saturday, trackday sunday, and again the following wednesday competing in the inter-universaties competition... anyways, got the car there saturday early... which is extremely rare for us, usually last minute touches happening at 2 in the morning!

http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140307_234120_zps68038f73.jpg
been a while since these two ladies were side by side
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140308_122121_zps57a48a78.jpg
actually remembered the bumper this time round
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140309_150836_zps473ecbbf.jpg
few pics of tynagh from various photographers on the day
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/1966145_688810144472578_1966385801_o_zps7d3e20a5.j pg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/1962596_10202872723732768_1976489209_n_zpsda46874f .jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/1173842_617126645026313_1534775340_n_zpsb0261688.j pg
Owly went doing a bit more land levelling with the front lip & left the bumper behind him
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/1901895_617594771646167_1545530472_n_zpsa5b83f18.j pg

Last thing in the evening, had a bit of a bump with another E36 & pushed in the rear right quarter panel... just as well I completely forgot I had a GoPro with me.http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/smack_zps3fa48f25.jpg


With tynagh not on again until May, we got a move on with testing the Methanol injection this weekend
all the kit setuphttp://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140321_194425_zpsf9b55a70.jpg

small 2.5L tank for now borrowed from another e36, have a 5L tank that was in the car originally as it had headlight washers & a few bits. when its all setup permanently that will be used instead
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140322_181903_zps5e038d02.jpg
controller temporarily setup for testing
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140322_181913_zpsa1dbd2f8.jpg


First methanol trial done with 50/50 methanol/water mix injected at 200psi, no noticable difference with small injector, switched to larger injector (x2 the GPH rating) and began to see mild differences.
Not not much quenching on low boost pressures either, so may be able to start using two injector nozzles together, increase the mix to 75% methanol and continue increasing the injection pressure to 300psi... Its becoming really noticable the boost pressure drops off after 3000-3500rpm so probably a turbo upgrade is the next step before dramatic differences are going to be had

[grange]

Or just pic up m3 running gear lol

[TorqueWorks]

Or just pic up m3 running gear lol

Id expect them comments after page 1... not now!

We had a 328i and a 323i both of which are now soldd on & sliding around tynagh & WGH.. having bought them pretty much to do power comarisons we have a lot more grunt in the diesel, + low running costs.. next up is getting an m3 and matching that for power..

Btw that engine, turbo, intercooler, injectors & diesel pump are still all factory fitted.. its still untouched so a lot more power gain to be had yet

[TorqueWorks]

Right, update

Indirect Injection Fun :)

Looking at what the guys are at in finland with the M21 engine trying to get better cylinder head flow, raising the headgasket is their way of going about it to get better cylinder head flow from their pre-combustion chambers (Swirl type chambers in the BMW's), that's lowering the compression ratio, but they're compensating by raising the boost pressure

Bit of theory on IDI Engines:
the idea of the pre chamber is air flows into the pre chamber in the compression stroke, the design of them in this engine causes a swirl in the pre chamber, hence the name swirl chamber is also used for this type of indirect injection chamber.. diesel is injected into the swirling air & mixes, that diesel partially ignites in the pre-chamber & creates a pressure that shoves the atomised fuel back into the main chamber. The main chamber is where it meets more air & the main combustion happens during the power stroke.



Looking at the design of the pre chambers in this engine, I think I can achieve a higher head flow by widening the passage to the pre-chamber about 20 to 30 precent, not having to raise the headgasket atall & therefor not really much drop in the existing 22:1 compression. It should help deliver the larger quantities of diesel into the main chamber a lot faster especially under high rpm's (reving to 6000 RPM currently). If it works the engine should be a lot more rev happy, a bit noisier, and with the quantities of diesel we're injecting should burn a lot more of it & develop more power :D

this could potentially cause dramatically higher combustion temperatures and higher EGT's as a result, but with water/meth injection in place that should lower the combustion temp so everything will be kept under control

pre chamber design
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/BMWPreChamber_zpsd1b3be03.jpg
pre chamber position in the head
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/CylinderHead_zps0193745b.jpg


taking this in mind we removed the spare engine we have for the drifter from the former dog kennel E36 we picked up a few months back. for a bit of experimental head work.
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140323_191219_zps59410544.jpg

block
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140329_212622_zpsb5f3862d.jpg

cylinder head
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140329_212651_zps75ad0d33.jpg

6 pre-chambers removed from the head, cleaned a bit & ready to get a go on the milling machine maybe next weekend
the entrance you see, that is going to be enlarged
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140330_005201_zpsfa67e01b.jpg

[TorqueWorks]

Loving this thread. I'm a massive fan of diesels and this stuff is truly fascinating. When your finished here pop over and do my car!


I like the way you think it will ever be actually finished lol

Anyways time for a bit of an update, Have been struggling to find time to get anything done recently with the buildup of coursework & final year project for college, as well as preparing for & attending assesments & Interviews for the Mercedes Formula1 team's Engine & powertrains division. Got through most of the hoops so far & down to final 3 in europe for 2 places with their electrical engineering team.. Would not mind working there :D #DreamJob

Anyways, the update:
Cylinder head fully stripped down & cleaned, being worked on in cleanroom conditions as you can see :P
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140419_214022_zps070b56ce.jpg
soaked everything in a mixture of diesel & petrol for a full week then boiled them, and finally used the die grinder to clean up the valves with steel wool... shiny :D
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140419_214055_zps0281c04c.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140419_214104_zps13b4fb43.jpg
even the shite that does build up on the intakes thanks to EGR was dissolved completely
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140419_214126_zps18ad930e.jpg


now down to the main job, enlarged pre-chambers on the CNC Milling machie
jig with a face surfaced perpendicular to the angle the entrances were, the reason is that you can set up the jig repeatedly setting this surface horizontal. this ensured every chamber was cut identically and any future chambers can be cut identically too.
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140426_125013_zps6c826b07.jpg

after machining
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140426_125125_zpsa48c081a.jpg

actually noticed slight variations in the casting of the chambers, these are the two that were most different... our cutting was in exactly the same position & precise across all chambers , measure the distance from the side to the casted groove in the pre-chamber and they all varied slightly, measure the distance from the side to the new machined entrance and they are identical.
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140426_125352_zps3328f5e1.jpg

before & after comparison
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/Comparison_zps5050f692.jpg

wont have time to go at this again until june

[Eoin k]

Fair play is all I've to say!

[TorqueWorks]

Was home from dublin for a few hours earlier today so I attempted something I've been figuring out for a while.... How to give this lady a Remap :D This older ECU is before the time of the now commonplace plug in remaps, these ladies have to be stripped apart and erased with UV light before programming.. Fuck That! Picked myself up an eprom reader/writer and a few new chips...
and this is what the ECU looks like stripped apart, notice the two chips with the stickers on them, thats actually covering the UV hole for erasing these
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/Maps/20140528_212236_zps9004db3c.jpg


chips out, read, and saved to a file then got to the hard bit, figuring out from a bunch of numbers, letters and locations how to distinguish a map from just empty space or other shite you dont need to know about and select it to make it into a 3d graph that can be looked at more visually... Headmelting to say the least, but more interesting than writing my thesis so I managed to figure some of them out
part of the memory dump on one of these eproms... Jibberish to most :P
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/Maps/ECUMaps_zpsf686a68e.jpg

then eventually you can learn to identify things and get really cool shite to show up, figure out how to convert them from hex to recognisable numbers and edit it... this is my modified torque limiter, one of the most basic maps on the ECU.. as you can see its RPM along the bottom axis, which I have increased from 4250 to 5100 :D and raised the injection quantity to maximum across the rev range :D
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/Maps/TorqueLimiterModified_zps0d900804.jpg

This is the boost pressure map, remember the boost pressure sensor reads Absolute pressure so 2550 is actually 1.55 Bar boost pressure, this map actually lowers the fuel as the RPM's rise which is probably helping to cause our boost pressure drop
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/Maps/BoostLimiterunmodified_zpsb03fa852.jpg

agressively modified... Im not concerned about smoke :P also notice the maximum boost pressure has been raised and the rpms raised
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/Maps/Boostlimitermodified_zps978e5103.jpg



I've flicked around in a lot more of these and fixed them to give me the diesel I want at high revs... Stuck these on the new eeproms earlier and stuck the ECU back into the car and just gave it a quick try... It worked! the car doesnt rev limit anymore it just keeps reving :D and gives me a wee bit of smoke now without my external chip turned on..... Didnt have time to take it for a spin just yet... but it should prove to be an interesting summer getting the hang of mapping:D One more week until I get to go back at the other engine too

[arronmoloney]

Your a brave man to go fiddling with the internals of the ecu ...fair fucks to ya :)

[TorqueWorks]

Right so mapping is going fairly well at the min, 15 different remaps tried each one learning something new and it turns out we're on the maximum the pump can deliver now which is fairly suprising, need more diesel:P The remap has livened the car up even more particularly due to the power at the higher rpm's.. I absolutely love the way it just keeps revving now which is feckin fantastic,it is considerably quicker now as a result.. We also calculated it did 2 MPG on the hillclimb.. yes 2!!

did a bit of a hillclimb yesterday on a forestry road to try out the power, it suprised us :D Torque!!!
http://youtu.be/ZXGRqCYU5V8

http://youtu.be/ZXGRqCYU5V8


and the development engine is coming along too, pre-chambers re-fitted and the intakes are getting ported & polished to improve intake flow for high RPM's.. Head to get skimmed and valves re-ground, she should be good to go for a trial.. no guarintee that it will work but fuck it we'll have a go!
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140610_194513_zpshj9jullt.jpg

[TorqueWorks]

Could never figure out why a brand new hydro handbrake cylinder would never work even after I was convinced that all the air was gone out of it.. pissed me off today again just looking at it so I took it apart & found two problems

firstoff, the pin is meant to get caught inside on a collar & unable to come out... whatever little chineese cunt put this one together he bet it into it rather than disassemble the whole thing again so it would never spring back like it was meant to.. straightforward fix just straighten it out from the inside

pic of the piece bet in
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140705_175221_zpsz0pfio42.jpg

problem 2 was a bit more of an issue, the seal on the back of the cylinder which acts as a non return valve from when you pull the Hbrake slightly until its released a chunk gone out of it, & not a sign of it anywhere :/
going to try Abbey seals for one but not holding out much hope.. balls of a thing its an odd shaped seal
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140705_184241_zpskejaisim.jpg

[Duck Drift]

Hi mate were ya get the paddle clutch? Need one for my tds
Cheers

[TorqueWorks]

Hi mate were ya get the paddle clutch? Need one for my tds
Cheers
getting them from the US, GripForce.com, F1 racing paddle clutch disc only. (BTW only get the solid discs from them, their sprung discs are worse than cardboard)



Suppose its worth updating this again, havent found much opportunity to get near this over the past two months really, too busy running the Dunmore Silage Day
Here's something we got upto, making plaques for the working machinery we disassembled 25 engines & made 100 powdercoated piston trophies
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140713_1834531_zps90d61e4e.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140730_2144061_zps738264ff.jpg
I dont have a picture of the finished article, but Stainless Steel bolts & a brass badge on the front.. here's the idea
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140730_2146181_zpsea9c964f.jpg


so back to it.. got another cylinder (Thanks EoinK)
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140714_231848_zpsmbrfzrst.jpg

but I wasnt going writing off an otherwise ok cylinder when Abbey Seals quoted me 15 euro to have a seal manufactured if I sent the drawings, so draw the seal I did
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/seal_zps2bf0da1b.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/Sealdrawing_zpsb8d98541.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140717_175304_zps4eog31hd.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140718_1756341_zps3aeb6aa0.jpg
and re-assembled
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140716_222243_zpsyn4o9gpc.jpg


then picked up a vnt turbo from a 215bhp 530d, in comparison with the original TDS turbo
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140713_110430_zpsufteoo4k.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140713_110436_zpsfd7jc0wq.jpg
exhaust just matches up perfect
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140713_104837_zpsljgu5hla.jpg

here's a comparison of turbos
Holset HX35 Case Puma , Garrett GT2260 BMW 530d, TD04 11G BMW325tds, Garrett T15 BMW318tds
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140713_105506_zpsdspyjqvt.jpg
I'd say the holset would be fine for big power figures on a dyno, but feck all good for this job a full power band, thats why we went with the 530d vnt turbo, it can vary between a small & big turbo effectively with the variable veins
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140713_141452_zpsdu9qypg3.jpg

and how I plan on controlling the vnt, my boost pressure sensor feeding to the arduino which controls a 180 degree movement of a servo motor, identical to the approach of the Hella controller on the newer version of the turbo. I have thought of simply boost controlling it mechanically but this way is much more adjustable & fine tuneable
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140725_2356181_zps548a1061.jpg

[mayotobo]

lovin the agri spec theme ha. it seems as though serious power can be got from these standard engines. ive a e34 525tds. just wondering if they have the same gearbox? looking for a new clutch and was thinking of getting one like what you got. standard clutch dosent like the EVRY mod ha ha!

[ELV-iS]

would love to see a dyno graph for this thing... a lot of work going into it...

the trophies look class btw

[TorqueWorks]

lovin the agri spec theme ha. it seems as though serious power can be got from these standard engines. ive a e34 525tds. just wondering if they have the same gearbox? looking for a new clutch and was thinking of getting one like what you got. standard clutch dosent like the EVRY mod ha ha!

you dont need to care about the gearbox, clutch disc is all you're interested in, here's what cars the clutch disc is in:
http://www.realoem.com/bmw/partxref.do?part=21211223678

Meant to be getting a few in a few weeks time, about 100 euro for the disc.

as for dyno graphs, after a bit more work, speaking of which: Bit of an update while I'm here

Tried fitting the turbo underneath & its just too big, its sitting on the engine mount
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140827_210544_zps7qpm2qwx.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140827_210458_zpsgyj07k5a.jpg

so flip the exhaust mani & spin the turbo to get the exhaust pointing back.. problem is now its not a bolt on job :/ what it looks like
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140827_213819_zpsafqfhqdy.jpg

lazer cut a few flanges to make up an adapter
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140829_193510_zps7wui6i4c.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140902_224933_zpsoakq0kuq.jpg
& die grind the inside with sanding cones until its 100% smooth flowing
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140902_225046_zps6jdu19am.jpg

and eventually it all bolts together
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140901_221028_zps5eees3pq.jpg

now next issue, Oil feed has to be on top & exit out the bottom so that required splitting the turbo & its going to be rotated most of the way around. uneven amount of veins so the dowel hole is going to be re-positioned in one of the two spots outlined below
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/e769cc17-b983-4836-a6b6-1b71dceaf7d5_zpsdd5d3c9b.jpg

then threw it up on a milling machine & bored the dowel pin out exactly where I needed it
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140904_202512_zpsb9qyxgur.jpg

how it all looks & where the servo is roughly going to be mounted
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140904_230105_zpsvrexyfyt.jpg

also.. FMIC :D
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140831_211638_zpsa0ko3yjk.jpg

no point in a big turbo & big intercooler without a big intake manifold aswell. Sort of taking shape
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140909_235959_zps23ncywuh.jpg

More maybe after the weekend

[mike e30]

cool job man. did u try a e34 525tds exhaust manifold as they are top mounted unlike the e36 mani. i should have one there if u want to try it out

[TorqueWorks]

cool job man. did u try a e34 525tds exhaust manifold as they are top mounted unlike the e36 mani. i should have one there if u want to try it out

Same part, same part number so no difference. Its fitted now anyways

[mike e30]

they must have just done the same thing as u flipping it upside down to clear the steering box

[TorqueWorks]

Anyways, Finally time for a well overdue update on this

No point in slapping on a big turbo & having a 2" restriction on the intake manifold, so the plan formed
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140924_223237_zpshojvyehz.jpg
& finished
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20141016_184256_zpsozmanjlb.jpg
then figured out the piping from the turbo to the manifold
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20140922_214816_zpss3lshi6s.jpg
then, the VNT Controller Servo motor being controlled by an arduino which is at the moment just reading boost pressure from a sensor & Mapped for the veins to be fully open at 1.5 Bar Boost
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20141003_183437_zpsh6xlvdj9.jpg
Turbo & servo in its final position, anyone notice the colour of the wires yet :nod:
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20141004_182245_zpshnqvwfqc.jpg
Oil feed fitted & EGT sensor added
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20141011_195748_zpsz5mkru2v.jpg
Then to test it out, this was recorded last friday night, working incredibly well boosting full under no load.... We picked the right turbo!! We were extremely suprised
https://www.youtube.com/watch?v=RuO6xWJaTpk

https://www.youtube.com/watch?v=RuO6xWJaTpk

saturday we stuck everything else back on & did a job on the cold air intake, straight in through the headlight
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20141018_183714_zpsbgjfvnyy.jpg
Bit of a job on the front bumper too, oh yea & 25mm spacers all round
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20141018_183832_zps4rtqjjhi.jpg

Completely Un-Tested we loaded up & headed to tynagh sunday morning to have a lash at a grip day & weed out any issues the car may have & test out the turbo & setup. Drift car come Track car huh?
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/20141019_124511_zpsxsm5s7du.jpg

Trying to keep it composed & in a straight line with 225 dunlop SP Sport road tyres on the rear was a challenge even in a straight line down the back straight in 4th gear, there was just so much torque and so much extra power the full way up through the rev range where the original turbo used to drop boost pressure this one just kept going
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/10580096_926371194058305_6056323538_zps1b17b974.jp g
changed over to wet grip tarmac tyres on the rear & it kept it a wee bit more straight, thats when the power gains really began to show with the speed I was getting down the back straight. Its hard to tell exactly what its like tho having been so wet for the tracktime we had
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/10622866_926373850724706_6392545335_zps59888573.jp g
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/10153164_926375247391233_2461945780_zpse6df3089.jp g

As the rain suddenly took a turn towards a downpour I had a wee bit of a moment on one of the hairpins saw the front bumper eating some tyres in the centre of the track, luckily intercooler escaped unmarked! Bumper will be fixed with a cabletie or two
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/10734283_926377944057630_1870420557_zps46238b6c.jp g

so.... What did we learn from it all? I spent some of the day getting the turbo close to perfect at 1.5 bar constant between 2000rpm and 6500rpm. Best bit is I ended up not opening the veins fully to keep it at 1.5 Bar which meens theres plenty more potential in this turbo yet :D.. 2 Bar & a bigger plunger in the pump next :D VNT Turbo For the WIN, best decision ever!! The servo did not melt sitting on the rocker cover & thats well tested after getting the stones driven out of her on sunday. All is good :D And a good few more ponies especially in the high high revs now.

On a side note trying to keep a car in a straight line when it has a suspension setup for drifting is extremely challenging. We'll be getting original wishbones sorted out for the next day & bring back in the camber for grip days

[Kruizer]

Great work man, some really good updates, look forward to seeing more.

[willm185]

2 quick questions for you there can you do the evry mod to a 318tds , and if the clutches from a 525tds fits the 318 as the standard clutch is useless thanks in advance

[TorqueWorks]

2 quick questions for you there can you do the evry mod to a 318tds , and if the clutches from a 525tds fits the 318 as the standard clutch is useless thanks in advance

Yes evry mod will work, but a Remap will liven up the Horsepower much more in higher RPMs as the ECU begins to lower fuelling gradually after 2500rpm

No clutch will not work much bigger dyameter in a 6cyl

[jonnyrb]

Love this, fair dues for going a different route, researching and trying things, id like to see what power this is making... keep the updates coming!

[TorqueWorks]

Right, to close out this thread from me, I have sold out my half of this to Owly as I have started a new project, a 330cd "M3d" (Click HERE (http://www.driftireland.com/forum/showthread.php?44527-BMW-E46-M3d-Drift-Build)).. That said, Owly will continue the work on this car (I hope) so this is his thread now. There is also another TDS Coupe Project by another member of the team who has helped with this project to date, so I will be posting updates to that also.. (Click HERE (www.driftireland.com/forum/showthread.php?44528-BMW-E36-M325TDS-Drift-Build))

Right so for my final update on this
The 2nd flywheel didnt hold up to the hammering it got during the last track day, so we got Flywheel number 3 machined up & in the car ready for the IGR Drift Day,
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/Screenshot_2014-11-16-00-40-042_zpsaauked4p.jpg
we also got methanol installed on the new manifold to keep everything cool
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/DSC_0004_zpsyoeladae.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/DSC_0005_zpsttwhvlyp.jpg
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/DSC_0009_zpsymwmvowz.jpg
new control panel made up
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/DSC_0063_zpsr0sw5jrf.jpg
& the LED Dash also hooked up for monitoring everything
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/DSC_0064_zpssaxqmzuv.jpg
the arduino sitting in behind doing its job controlling the turbo to perfection all day, wired with some of the finest shielded Rosenberger cable (Genuine OEM for new BMW's may I add :P)

And to sum up our day at the IGR Drifting event in one picture
http://i872.photobucket.com/albums/ab288/nosmokenopoke/E36%20325TDS%20Smoke%20Machine/DSC_0010_zpsletz2nvp.jpg
Turns out Oil Coolers dont like being dragged along the ground... Put every bit of oil out onto the track in moments as soon as it ruptured!, after that we had nothing but oil pressure problems :/ ended up being towed off the track a second time with Oil pressure issues & that was that for the day :/



So thats all from me on this project, its Up to Owly to continue the work from here & keep this sideways