Finally took the car off the jackstands today to take it to the muffler shop for them to fab up my 3in exhaust. I had about a 1foot pipe coming off the turbo just to get the car running and to the shop. I didn't have the vacum lines hooked up to the wastegate and bov yet so i didnt get on it at all. While I was going over the bridge and let off I could hear the turbo de-spooling and i was like "yes finally!" I'll be getting the car back tomorrow to finish up the install and begin tuning! I'll post some pics as well.

The setup is all custom and I will be running ~10psi on a stock compression/headgasket 2.5l obdII m52. I'll be tuning with the greddy emanage ultimate, using the maf in blow through then clamping it and tuning via the map sensor.

Here's some of the hardware:

-gt30r .63ar
-spa manifold
-spa wastegate
-greddy type s bov
-greddy type s boost controller
-4in xspower (ebay) intercooler



Feels good to finally belong in this section of the forum!!:buttrock

damn 18 views and no replies jeez. let me be the first to say Congrats :buttrock

looking forward to a dyno :D

Congrats :buttrock Lets see some pics of the setup.

Congratz! please post pics and vid... How much money did u spend ?

Congrats! Big accomplishment....way to go man! Lets see some pics...that must be an awesome feeling, can't wait to experience that day.

:redspot

YES!! Finally.......Would like to see some pics as well.

Congratz! please post pics and vid... How much money did u spend ?

I decided to stop keeping track of it... probably best I did lol
It's all the little stuff that keeps adding up... today 60bucks at advanced auto for an air filter, gasket material, flex hose, ect...


I'll get some pics and more info up tomorrow evening when I get the car back.

GT30R I had for a while and ohhhhh man are you in for it. Congratulations! Must see pics! Wait until you feel that boost kick in on that DBB turbo. WahoO! :buttrock

congrats!!! I'm glad to see a true 323is turbo setup finally!

I can't wait to see some official numbers of it when you're ready.

-Ron

awesome news! congrats

Congrats! Looking forward to more dynos and turbo shenanigans from you!!!

I know how hard you worked on the emanage. Enjoy the fruits!

Awesome! Congrats! Can't wait to see the dyno. :buttrock

BTW how many miles are on the motor and how long has it taken to get to this point? Thanks

congrats!

congrats!!!!

Awesome! Congrats! Can't wait to see the dyno. :buttrock

BTW how many miles are on the motor and how long has it taken to get to this point? Thanks

102k miles and this monday will make 2 weeks of working on the turbo install. I didn't work on it every night though. It could have been done in a week. Many hours involved in getting the emanage ultimate to work because of the injector issue.


Ok got the exhaust done and have been just slighty leaning on it. Love the boost so far. I have tbolt clamps and silicon hose to replace the rubber crap I got from Joe(Midnight Auto*ucks) but for now i have his clamps and hose on the intercooler outlet side. I blew a hose off 4 times already.

After running the car today I now have a slight oil leak coming from the fitting that is tapped into the oil pan. Going to have to drain the oil tonight and come up with something to stop the leak. We threaded the oil pan and used the white stuff on the fitting threads. After tighting it all the way we put jbweld on the bottom half of the fitting. Looks like it is leaking from the top part of the fitting. I'll re do that tonight. Any suggestions on what to use to secure the fitting in the oil pan?

Ok now I'll upload some pics...

http://img233.imageshack.us/img233/2269/dsc0041pg1.jpg
http://img233.imageshack.us/img233/2310/dsc0043bd4.jpg
http://img141.imageshack.us/img141/9541/dsc0040ee9.jpg
http://img82.imageshack.us/img82/4300/dsc0074xq3.jpg
http://img82.imageshack.us/img82/9355/dsc0016fa3.jpg
http://img83.imageshack.us/img83/8014/dsc0033vb3.jpg
http://img82.imageshack.us/img82/1017/dsc0034ez3.jpg
http://img83.imageshack.us/img83/6330/dsc0038rh7.jpg

AWESOME! Congrats dude, I was pissed when my motor overreved cause I wasn't able to realize my turbo 323is dream, so I'm very glad someone has accomplished it! Keep us posted! Be easy on the motor, I got a chance to look at the stock rods and those will definetly be the weak point.

Representin ruff raleigh. You should hook the kite tube up to the tow hitch on the back of that when its finished. I'll have to come check it out sometime. I have an interested buyer for my car though, so im not sure how much longer i will have it...

nice clean exhuast and I am liking how you are staying with the double tip look.

WOW! that looks great! congrats man!

Looks awesome!!

Be sure to get us some dyno graphs or better yet

Race vids :evil2

Awesome man! Can't wait to see some dyno numbers! I'm considering a turbo'd E36 to be my next car..

thanks for the comments guys!

I'm trying to get the wastegate and bov issues fixed. I have compressor surge then hear the bov. The wastegate isn't opening up either..(i made 12psi on stock compression!!) I think the reason for these problems is because I used 1/8in vacuum line instead of the recomended 1/4-5/16in

I will say the greddy emanage ultimate is a very cool program. The datalogging is great. If I only had a better handle on tuning...

Also I have to hook up a catch can for the additional blow by. The little catch can under the manifold is full and some oil got sucked into the manifold causing it the car to smoke on start up and since the can is full it leaked out some oil. I'm going to drain it tonight and install the catch can wednesday when it comes in.

Well, back to the garage!

Huge congrats man! You'll love every minute of it.

God you suck... You got the emanage working too... I sold mine already... Gonna just go standalone one of these days....

Nice.

- You got emanage working. Nice. Did Joe actually send you a pnp harness or did you hard wire it yourself. I haven't kept up with the Emanage drama in a while.

- Nice drain location. It seems everyone moves it really far forward in the pan...this seems a more logical place for it. Although yours does look like it might a bit too high...that space near the 'lip' on the pan is where the internal upper baffle sits.

Looks good man... keep it up.

Nice.

- You got emanage working. Nice. Did Joe actually send you a pnp harness or did you hard wire it yourself. I haven't kept up with the Emanage drama in a while.

- Nice drain location. It seems everyone moves it really far forward in the pan...this seems a more logical place for it. Although yours does look like it might a bit too high...that space near the 'lip' on the pan is where the internal upper baffle sits.

Joe was absolutley no help at all in the emanage install. I wired everything myself and figured out how to make the injection work without the ecu shutting down injectors. He sent crap couplers and hose clamps which I replaced w/ silicon and t-bolts. His piping was usable however.

Yeah I had to drill out some of the baffle to make room when we threaded the oil pan hole. Nothing major though. I re-sealed the oil pan fitting and fixed the oil leak I had.

Oh yeah I fixed the wastegate issue. It only needed one vacuum line going to it. Now tuning will be alot easier sine it isn't trying to continue to make boost throughout the rpms.

BUMP For a good thread.
Looking forward to seeing some dyno's :D

man this emanage is nothing at all to tune so far. I'm still having wastegate issues. I think it might be too small for the amount of air I'm flowing. I think it is like 32mm. The boost comes on strong until about 6psi then it fluctuated till about 10 w/ a less steep line. I know this from looking at the map sensor line plot. The datalogging is such a great feature.

I'm shooting for a dyno next week. More pics to come in the next few days.

man this emanage is nothing at all to tune so far. I'm still having wastegate issues. I think it might be too small for the amount of air I'm flowing. I think it is like 32mm. The boost comes on strong until about 6psi then it fluctuated till about 10 w/ a less steep line. I know this from looking at the map sensor line plot. The datalogging is such a great feature.

I'm shooting for a dyno next week. More pics to come in the next few days.


so what did you have to do to get the e-manage to work? can you start a new thread with info on it? it would be nice not to have to read through a novel to get the correct info.

I'm still having wastegate issues. I think it might be too small for the amount of air I'm flowing. I think it is like 32mm. The boost comes on strong until about 6psi then it fluctuated till about 10 w/ a less steep line.

Look at the circled areas in the picture below. That's your wastegate issue. You have horrible flow through the wastegate piping, leading to the boost creep issues you're seeing. You need to use smooth bends, not square ones.

I'll make a new emanage thread sometime soon when I get a minute. I had to make a resistor box in order for it to work though.

Thanks for the help Nick. That piping is in the way of the bar that goes across right about there, so I was going to get the shop to redo that and just make it open to atm. I'll get them to use smooth bends next time around.

Look at the circled areas in the picture below. That's your wastegate issue. You have horrible flow through the wastegate piping, leading to the boost creep issues you're seeing. You need to use smooth bends, not square ones.
dmb882: Yup! Just get rid of those lame pipes for now...weld shut the hole in downpipe...wastegate to atmosphere and let her rip! :buttrock

Wow, i didn't see this thread till now but congrats on getting it up and running and I think you are truely the first person to get E-manage Ultimate to work:buttrock

rock on mang!

dmb882: Yup! Just get rid of those lame pipes for now...weld shut the hole in downpipe...wastegate to atmosphere and let her rip! :buttrock


Yup thats what I'm going to do!

Whoa, interesting wastegate piping! Congrats man!

Look at the circled areas in the picture below. That's your wastegate issue. You have horrible flow through the wastegate piping, leading to the boost creep issues you're seeing. You need to use smooth bends, not square ones.

Can you say U-Bend? ;)

lol i left the car at the exhaust shop and just told them to route it back to the exhaust. Thats what they came up with.

Good thing is it is going to be history and dump to atm!

lol i left the car at the exhaust shop and just told them to route it back to the exhaust. Thats what they came up with.

Good thing is it is going to be history and dump to atm!
An exhaust shop did that? :lol Man they must be smoking da good stuff mon! :smoke3

LOL Cameron.


I was actually about to post about the poor airflow on that wastegate pipe but I guess you guys got it first :( A lot of those type of small overlooked issues are covered in that Maximum Boost book.


Congrats dmb. Who's garage is that?

lol i left the car at the exhaust shop and just told them to route it back to the exhaust. Thats what they came up with.

Good thing is it is going to be history and dump to atm!

that will help but you'll most likely need a bigger wastegate too. 38mm atleast.

Those pics were taking at the exhaust shop ( EZ Muffler) with the car on the lift. I'm in the big ole town of Rocky Mount, NC. Sure you've never heard of it.

awesome man!! Keep up the good work. Everything looks nice.

Can't wait for numbers

Look at the circled areas in the picture below. That's your wastegate issue. You have horrible flow through the wastegate piping, leading to the boost creep issues you're seeing. You need to use smooth bends, not square ones.


So I had the wastegate piping re-done today. It has about a 1.5in pipe coming off the wastegate. I still am having the boost creep issues. I hear the wastegate opening about 6psi but it continues to make boost. This seems to make me think it is not the spring setting, but the wastegate itself isn't large enough.

So I had the wastegate piping re-done today. It has about a 1.5in pipe coming off the wastegate. I still am having the boost creep issues. I hear the wastegate opening about 6psi but it continues to make boost. This seems to make me think it is not the spring setting, but the wastegate itself isn't large enough.


Great work dmb882 :buttrock
Now you have those nasty right angles (almost) removed form teh WG piping I reckon you need to get a 38mm or larger WG :)

Good Luck!

What mm is the Spa wastegate and what diameter is the piping from mani to wastegate? Sounds too small for low boost if you have creep when going to atmosphere.

dumping to atmosphere is more likely to creep than dumping back into the exhaust.
The SPA gate has a 38mm piston.

dumping to atmosphere is more likely to creep than dumping back into the exhaust.
The SPA gate has a 38mm piston.


Well what should I do?

dumping to atmosphere is more likely to creep than dumping back into the exhaust.
Why?

cause of the back pressure of exhaust gasses?

cause of the back pressure of exhaust gasses?
The theory in my mind says backpressure should increase the likelihood of boost creep.

I initially thought that the exhaust flow might create a local vacuum to suck the wastegate flow into the exhaust pipe.
Then I thought about back pressure like you did, which made me think I was wrong on the local vacuum affect.

I guess we'll have to wait.

the purpose of the wastegate is to dump the excess energy from in front of the turbine. Another way of looking at this or stating this is that the purpose of the wastegate is to reduce the deltaQ avaliable at the turbine. The turbine gets its power from the change in enthalpy across it. So taking energy from in front of it is one way. Adding energy behind it is another. So dumping the wastegate back in behind it will change (further reduce) the energy flow potential across the turbine.

what wastegate do I have? if it is the compact gate then on innovativeturbo it says that is like 32mm...

what wastegate do I have? if it is the compact gate then on innovativeturbo it says that is like 32mm...
you have the *USA style* wastegate.

http://www.innovativeturbo.com/pages/cart_itemDetails.asp?sku=WG-USA1

that isn't the wastegate I have. I looked in your group buy thread and it said compact gate for 210.

I need the usa style one if you can swap me out and I pay the difference or whatever

I'm taking it off tomorrow and measuring the valve to confirm this.

I'm going to be moving my 38mm tial wg up top with my spa manifold and then running it open to atmosphere. I have a small leak right now, so I figured while I have it off I might as well change it to make more power and sound (car is way too quiet right now!).

I'm just going to run a profec B boost controller and hopefully that'll take car of any over/under boost issues.

http://img212.imageshack.us/img212/97/dsc0014uv2.jpg

25.4mm=1in 1.25x25.4mm~31mm


Looks like I'll be getting a 38mm wastegate now...

wow congrats. that looks like a great setup. when you get everything finished up pleaseee make a video or take some sound clips. thanks for giving 323is owners like myself something to dream about haha:buttrock

ah, yes, that is the compact. From the pic it looked like a bigger red top like the USA. (I didn't recognize the SN for some reason as being you dan... sorry about that.)

The compact is listed as a 35mm gate. (33/x35). its the same wastegate we use on bbaz's car, so I'm suprised its creeping like this with a gt30R.
The compact has an adjuster spring on the top. I assume that is already as loose as it can go, right?

http://img212.imageshack.us/img212/97/dsc0014uv2.jpg

25.4mm=1in 1.25x25.4mm~31mm


Looks like I'll be getting a 38mm wastegate now...

Holy...:wow So they call that a 35mm? Where do they get the other 10mm from?

It's fine Michael. On Innovatives site the compact is listed as 1.25in (31mm). It is probably a tad larger than 1.25 and closer to 32mm. Either way I bought a 38mm xspower w/ a 6psi spring today. I was going to get the tial but the only tial they had in stock had a 13psi spring in it. I needed a wastegate today because the cars going to the dyno tomorrow.

I hope this tial fits... the space looks tight, but the bolt spacing should line up against the flange. I'm about to find out in about 5min...

i'm just now stumbling across this thread and i must say... i am the definition of jealousy right now

sorry for the random post... best of luck sir

tial knock off wastegate fits perfectly!!! now lets see if it works..

Well I would never think I would be so happy to only see 6psi! I gota change plugs, hook the boost controller back up, and get this thing on the dyno tomorrow! :)

Heres the view from my dad's e55 amg's side mirror... Maybe he will be in mine in the near future! Well maybe after low compression and more boost lol

http://img54.imageshack.us/img54/1255/dsc0011st5.jpg

Yay a local turbo guy!! And a succesful emanage user to boot, you should come to some of the meets we have around, I would love to checkout your car.

It's fine Michael. On Innovatives site the compact is listed as 1.25in (31mm). It is probably a tad larger than 1.25 and closer to 32mm. Either way I bought a 38mm xspower w/ a 6psi spring today. I was going to get the tial but the only tial they had in stock had a 13psi spring in it. I needed a wastegate today because the cars going to the dyno tomorrow.

I hope this tial fits... the space looks tight, but the bolt spacing should line up against the flange. I'm about to find out in about 5min...

a tial, or SPA USA, or turbosmart, or tial knockoff... any of those will fit. some may be a touch tighther than others. but they'll fit. the flange will fit for sure. and some of hte ones with slightly bigger "heads" may touch the chassis heat shield slightly.

This is why the wg downpipe is slightly different on the manifold now than it was before. It used to only fit the SPA compact. Move things forward in the engine bay slightly... a touch more downward angle, and voila. :)

Well I would never think I would be so happy to only see 6psi! I gota change plugs, hook the boost controller back up, and get this thing on the dyno tomorrow! :)

Heres the view from my dad's e55 amg's side mirror... Maybe he will be in mine in the near future! Well maybe after low compression and more boost lol

:buttrock I'm very happy for yoU! I can't wait to see the dyno sheet! Nice setup! My in-laws live in Columbia, SC and we always fly into Charlotte. Not sure how far you are from there but when I am out there I need to look you guys up to try and meet and check out your cars. :buttrock

Yay a local turbo guy!! And a succesful emanage user to boot, you should come to some of the meets we have around, I would love to checkout your car.

I'll be moving to Raleigh in about a week as I will be going to NCSU.

:buttrock I'm very happy for yoU! I can't wait to see the dyno sheet! Nice setup! My in-laws live in Columbia, SC and we always fly into Charlotte. Not sure how far you are from there but when I am out there I need to look you guys up to try and meet and check out your cars. :buttrock

Cam, just bring your car with you on the plane... that way you can give the eastcoast some inspiration!! Charlotte is about 2.5hours from Raleigh I think. Let us know when you head this way, I'm sure we could put something together.

stock 172rwhp 169rwtq

6psi 240rwhp 236rwtq

ill update later as im on a pda now but hell yea!

:buttrock That's wicked man!:buttrock

Really similar numbers to mine. I didn't know your car was stock at 172whp I thought they were all around 160-165. Are those SAE corrected? Huge props!!

U should race your dad's e55 v8 komp. .vs. your car and post the vid? :buttrock





Well I would never think I would be so happy to only see 6psi! I gota change plugs, hook the boost controller back up, and get this thing on the dyno tomorrow! :)

Heres the view from my dad's e55 amg's side mirror... Maybe he will be in mine in the near future! Well maybe after low compression and more boost lol

http://img54.imageshack.us/img54/1255/dsc0011st5.jpg

http://forums.bimmerforums.com/forum/showthread.php?t=580439

new thread as I'm making more progress and this isn't the first drive any longer..