BMW 325TDS Project Smoke Machine

[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 Torque!!!
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!

[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


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

[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


I dont have a picture of the finished article, but Stainless Steel bolts & a brass badge on the front.. here's the idea



so back to it.. got another cylinder (Thanks EoinK)


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




and re-assembled



then picked up a vnt turbo from a 215bhp 530d, in comparison with the original TDS turbo


exhaust just matches up perfect


here's a comparison of turbos
Holset HX35 Case Puma , Garrett GT2260 BMW 530d, TD04 11G BMW325tds, Garrett T15 BMW318tds

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


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

[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



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


lazer cut a few flanges to make up an adapter


& die grind the inside with sanding cones until its 100% smooth flowing


and eventually it all bolts together


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


then threw it up on a milling machine & bored the dowel pin out exactly where I needed it


how it all looks & where the servo is roughly going to be mounted


also.. FMIC


no point in a big turbo & big intercooler without a big intake manifold aswell. Sort of taking shape


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