Africa's First Active Autowerke kit build begins

[Matt Q]

Hey Folks

Some may have seen my pre-supercharger posts... well pre-supercharger no more.. the postman arrived today and what a lovely box of goodies he had

http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/LastImport-0.jpg

http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/LastImport-19.jpg

http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/LastImport-4.jpg

http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/LastImport-7.jpg

http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/LastImport-5.jpg

The garage began stripping almost immediately, and these pics where taken tonight at 10pm when they finally kicked me out - ha ha

http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02409.jpg

http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02410.jpg

http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02417.jpg

http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02410.jpg

We could install it without removing the whole front of the car but this just makes it easier to see everything and as this is our first install they guys are gonna take it slow and steady and make sure they can see everything 100%. the will be building all of tomorrow (night time for most of you) so I'll have loads more to post by your pm tomorrow... we are aiming to be laying down some power before the weekend....

I am so bloody excited i can't tell you, finally joining the FI club - yeeehhaa!

[spiz]

u doing it big gl

[Activ3]

sweet! GL!

[Saintly]

Congrats Matt:thumbsup:

[OptimusPrime]

sounds like a lot of work and a lot of fun! good luck!

[Miami///M3]

GL on the kit....

[brycerichert]

hurry, hurry.

[Matt Q]

Congrats Matt:thumbsup:

Thanks dude :)

And thanks for all the cool advice so far... we'll be burning midnight oil to get the install up and running soon.. then I'll be chasing you down for info on reaching those elusive numbers you're posting !!!!

It feels so awesome finally standing on the doorstep of the FI community

[Matt Q]

Hey Guys

The new high flow injectors are now in and the charger and charger belt is in place.... more to follow later

http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02422.jpg

http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02423.jpg

http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02425.jpg

http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02427.jpg

http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02429.jpg

http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02432.jpg

[steelgrey330ci]

looking good champ, enjoy it and be safe

[silver///M3]

Congrats, looks great.

[steelgrey330ci]

What stage did you get ?

[Matt Q]

Stage 2 gen 3

Got the kewl trunk mounted methanol/watter fogger thingy

http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/LastImport-2.jpg

[Jean@ActiveAutowerke]

Looks like Christmas cam early. Congrats and enjoy.

[steelgrey330ci]

nice stuff, I look forward to some numbers you down over there.

[Matt Q]

Looks like Christmas cam early. Congrats and enjoy.

Amen!! for anyone thinking of going the AA route... i cannot stress enough the incredible build quality of this kit.. an uniformed person who looks under the hood will seriously not even know it's there.. the look is so professional and so OEM and everything just fits into place.... so sweet!!!

Cooling in
http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02437.jpg

Last tweaks on the charger
http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02440.jpg

Fitting the plenum
http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02441.jpg

Minor trim to fan housing
http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02444.jpg

Time for piping
http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02445.jpg

Piping done under the car
http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02447.jpg

Running pipes up to the charger
http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02451.jpg

And She's In!!!
http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02455.jpg

All that's left for tomorrow is to fit the intake, run the meth pipes, fit the methtank and finally put the other car bits back in and run the software

http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02459.jpg

[project]

congrats:thumbsup:

[Bimmer ///man]

SWEET! That is gonna be fun

[Xavi_328ci]

Hope you enjoy it!

[sheefo2k]

almost done

[Titan 3]

Welkome to the darkside, sir!! Kit looks great!

[Matt Q]

so close yet so far..... I just hope we get to hear her today :)

[phrozen06]

That's a bad A$$ AA Kit.

[Saintly]

You finished it yet or what.....:)

[Matt Q]

No Man... the damned time difference is a headache as we have to wait till the pm to get maps from their techies.... last I checked last night, Zaid was waiting for our tuning info... the car is running so she just needs the new map and we'll be ready for a road test.... everything is in.. just haven't put the bumper and lights back on until we pressure test the system

[Matt Q]

Except for the final connection of the meth tank.. the whole kit is now in and running.. software is loaded.. here are the last pic and some initial clips..

Now she's off to the street for a 100km run in followed by the final Dyno run.. numbers to follow later today :)
:excited:

I just gotta say..... :bow: to Zaid and the team here at Zeemax and of course :bow::bow: to Active Autowerke

Tank In
http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02468.jpg

Running Meth Lines
http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02470.jpg

Meth Happy Switch
http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02473.jpg

Charger Oil Pump in
http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02475.jpg

Temporary Filter On (Waiting for another one form local supplier)
http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02476.jpg

and the first clip :)

http://www.youtube.com/watch?v=-HPAlLNHvC8

Gotta love that intake sound

http://www.youtube.com/watch?v=t5eeZ8zqYWw

[tim-m3]

:drool:

[idolized]

that's beautiful! I can see you at every stop sign/stop light doing a :burnout:

[zracer196]

Great job! Did you do this mod while you were at it??

Easy and quick...

http://www.m3forum.net/m3forum/showthread.php?t=205074&highlight=blow+valve

[zracer196]

Also,

On decel...the whoosh does not sound smooth or constant. I think M34U2NV had this problem too. It was due to the vacuum hoses being switched around leading to the BOV VALVE. There are two rubber hoses...I think someone said AA was not clear on this in the instructions.

It sounds different than mine...Of course my bumper is on, etc. Maybe that masks the intake noise some??

Just my .02.

[Matt Q]

HEYA!

Nope.. been in contact with Saintly about upping boost later on but I'll run it as god.. er AA intended ( :) ) at first and then see if the shift lag bothers me before venting to atmosphere. I'm not one to 1/4 mile the car.. more into mountain passes and track driving... so I'll see if the shifting lag bothers me or not... also need a while to adjust to the power... I have one last late meeting now and am heading to fetch the car at 7pm.. will post the first dyno figures this evening!!!!!!

[Dannyncc]

dyno result? Video on track or street please.. OUch:drool:

[Matt Q]

:tsk:

Ok so good news

The Zeemax team finished the whole Meth setup

http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02478.jpg

http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02480.jpg

and finally got her back in the dyno

http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02485.jpg

Only once we got the pressure really going did we notice water coming out of a hairline crack on the intake manifold :( :(

After swapping it out with another one (we ordered 2 kits so we'd have backup of everything) we discovered the same thing again... the cracks have kept us to a maximum boost of 7.2psi for now but we'll get it sorted and come back for more...

Here's the first Dyno chart for now.. please bare in mind that these are at the engine not wheels to give us a comparison to stock figures (which are engine power not WHP)

http://i245.photobucket.com/albums/gg48/breakbeatzboy/AA%20Stage%202%20Arrival/DSC02491.jpg

355.1KW = 476HP
480NM = 354FtLb

Not shabby at 7.2psi !!!! Frankly I'm very happy for now.. I'm sure we'll get loads more once we sort all the system leaks and get the boost up to 9psi... I'll post some vids tomorrow when I collect her a take my first FI drive

[jtrejo]

sux about cracks, is AA going to replace them?

[///JTM3]

You have the vacume that goes to the Bypass Valve connected back wards....
The Vacume line is suposed to be connected at on the bottom... Nothing connects to the stop one...

[Saintly]

Hey Matt, sorry to hear about the cracks, but can you be more precise...

[zracer196]

JTM,

That is what I saw and told him in post #30...

BTW...Love the baby seat base next to the alcohol tank in the trunk! lol I know those all too well!

[Matt Q]

Hey Matt, sorry to hear about the cracks, but can you be more precise...

There appears to be a couple of hairline cracks on the weld of the intake manifold.. we wouldn't have seen them unless the water/meth system was in.. we saw water beading under low boost and misting out under load.. we noticed this while dynoing the car .. this would definitely contribute to the lower boost

You have the vacume that goes to the Bypass Valve connected back wards
The Vacume line is suposed to be connected at on the bottom... Nothing connects to the stop one.

I'll check on this, thanks a lot :)

sux about cracks, is AA going to replace them?

I'm sure they will, once we make sure that those cracks are in fact the problem.. perhaps they can ship out replacements so we can ship back the crack head kits :)

[Matt Q]

JTM,

That is what I saw and told him in post #30...

BTW...Love the baby seat base next to the alcohol tank in the trunk! lol I know those all too well!

oh... you also meant the vacume hose.... duh! my silly.. ok will change this ASAP


Baby seats.. lol..yeah who says you can't have a high speed family-vagen!!

[Matt Q]

just checked now... we originally put the vac pipe on the wrong connection but when it dynoed it was on the correct (lower) one

see pic

So I recon the low boost is purely the result of leakage .... :bawling:

But the power is still great.. I'll drive it this weekend at 7psi and take it back next week to aim for more

[Matt Q]

We just got word from AA.. the leak is a super rare event that has only happened once before... they immediately offered to ship replacement manifolds and get our back once they have arrived... I must give a huge thumbs up to their service and support thusfar, it has been awesome... and as for the gear :drool:

Took a test drive just now.. the sound is incredible and the car just pulls and pulls like there's no tomorrow. I have an extremely firm suspension setup and the extra torque this kit gives me just pulls it all together so nicely.. this is how an ///M should feel. Sigh!!! life begins with boost...

[lrinco01]

Wow,

I remember that feeling as if it were yesturday!

congrats!

but just as you admit in your Sig, you'll be craving MORE power sooner than you think or care to admit.... stay safe man

[Matt Q]

Thanks dude... didn't have much time to try the kit today but the hour of driving I did get was mind bending.. I really cannot believe the difference over stock and so clean and linear.. the pull is just bloody delicious, especially over 5500 rpm when things REALLY get fun :) YEEEEEHHHHHAAAAAA!!!

[Saintly]

Nice work Matt, enjoy mate and your right it all starts with boost:excited: