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Old 05-26-2014, 06:17 AM   #1
Davew
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ESS TS running on 9.5 psi on stock TS2+ Tune

Machined up a couple of pulleys, one for myself, one for another member @78mm.

Neither car has blown up yet, I think it would be safe to say both of us have tried

Has made a nice difference, the dual mass squeal has moved from 3200rpm, to 2800rpm moderate shift, top end wise, feels like the car has picked up an extra 500rpm, hard to describe, boost punches to 10psi pre laminova's, and that last stage of the rev range where it pushes to 11.5psi feels tough.

Still haven't fitted the headers yet, but they are ready to go. Need a few days off to fabricate the rest of the system.

Have kept the primaries stock s54, into the collectors which are now 2.5 inch.

Thoughts at the moment is to run two 2 1/2 100 cel cats, into a Y, then 3 inch all the way to the muffler, then back to twin 2 1/2 inch out the muffler.

There will be a hot dog in the 3 inch to try and keep a handle on drone.

Last edited by Davew; 05-26-2014 at 06:20 AM. Reason: Sorry guys, can this be moved to the Aussie forum???
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Old 05-26-2014, 06:47 AM   #2
t651
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Old 05-26-2014, 08:51 AM   #3
GuidoK
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Very interesting.
So you get 10psi pre laminova with 78mm pulley?

How do you make the PK multirib profile?
I have a lathe but I'm not an experienced machinist, but I'm planning to make a pulley on my own. Is there a special bit/tip for that profile?
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Old 05-26-2014, 09:00 AM   #4
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Quote:
Originally Posted by GuidoK View Post
Very interesting.
So you get 10psi pre laminova with 78mm pulley?

How do you make the PK multirib profile?
I have a lathe but I'm not an experienced machinist, but I'm planning to make a pulley on my own. Is there a special bit/tip for that profile?

well I have a 79mm pulley and use the TS2+ tuning and belt.....


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Old 05-26-2014, 09:45 AM   #5
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Quote:
Originally Posted by GuidoK View Post
How do you make the PK multirib profile?
I have a lathe but I'm not an experienced machinist, but I'm planning to make a pulley on my own. Is there a special bit/tip for that profile?
There are special tools out there, but they're probably not cheap:

http://www.toolflo.com/cats/AUTOMOTIVE.pdf

Here's a thread on PM I found:

http://www.practicalmachinist.com/vb...e-help-196906/
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Old 05-26-2014, 01:16 PM   #6
Davew
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Just ground a piece of tool steel to the correct profile.

11.5psi pre laminova's peak, I was peaking at 10psi with the 81mm pulley.
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Old 05-26-2014, 01:20 PM   #7
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Quote:
Originally Posted by Davew View Post
Just ground a piece of tool steel to the correct profile.

11.5psi pre laminova's peak, I was peaking at 10psi with the 81mm pulley.

nice boost, but I think you get this boost because your Stage 3 cylinder head.....


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Old 05-26-2014, 01:40 PM   #8
Davew
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Quote:
Originally Posted by Davew View Post
Machined up a couple of pulleys, one for myself, one for another member @78mm.

Neither car has blown up yet, I think it would be safe to say both of us have tried

Has made a nice difference, the dual mass squeal has moved from 3200rpm, to 2800rpm moderate shift, top end wise, feels like the car has picked up an extra 500rpm, hard to describe, boost punches to 10psi pre laminova's, and that last stage of the rev range where it pushes to 11.5psi feels tough.

Still haven't fitted the headers yet, but they are ready to go. Need a few days off to fabricate the rest of the system.

Have kept the primaries stock s54, into the collectors which are now 2.5 inch.

Thoughts at the moment is to run two 2 1/2 100 cel cats, into a Y, then 3 inch all the way to the muffler, then back to twin 2 1/2 inch out the muffler.

There will be a hot dog in the 3 inch to try and keep a handle on drone.
Quote:
Originally Posted by jdjg View Post
nice boost, but I think you get this boost because your Stage 3 cylinder head.....

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There are a number of factors that will affect boost levels, though Asbjorn has posted in other threads that 10psi pre laminova's is normal/ within range.

I would anticipate a slight drop with the new exhaust, will see. Current exhaust is decatted.
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Old 05-26-2014, 01:43 PM   #9
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Originally Posted by Davew View Post
There are a number of factors that will affect boost levels, though Asbjorn has posted in other threads that 10psi pre laminova's is normal/ within range.



I would anticipate a slight drop with the new exhaust, will see. Current exhaust is decatted.

next moth I will install a custom 3" SS single pipe exhaust, very similar to my current 2.5" SS custom single pipe exhaust and will post the result in performance and boost


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Old 05-26-2014, 04:11 PM   #10
GuidoK
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Quote:
Originally Posted by Davew View Post
Just ground a piece of tool steel to the correct profile.
So you do that by trail & error? :
Grind, and see if it fits the existing pulleyridge (by eye), and if not grind a bit more?

Or do you know what angle the PK profile has and you have some tool/setup that can grind a tip in a specific cutting angle?
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Last edited by GuidoK; 05-26-2014 at 04:12 PM.
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Old 05-26-2014, 04:17 PM   #11
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If you can grind a tool to a profile that matches exactly by eye, it's probably close enough.
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Old 05-26-2014, 04:47 PM   #12
Davew
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Quote:
Originally Posted by GuidoK View Post
So you do that by trail & error? :
Grind, and see if it fits the existing pulleyridge (by eye), and if not grind a bit more?

Or do you know what angle the PK profile has and you have some tool/setup that can grind a tip in a specific cutting angle?
No trial and error, angle gauges and tool and cutter grinder.
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Old 05-26-2014, 06:16 PM   #13
cosmos328Ci
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Wink

Quote:
Originally Posted by Davew View Post
Machined up a couple of pulleys, one for myself, one for another member @78mm.

Neither car has blown up yet, I think it would be safe to say both of us have tried

Has made a nice difference, the dual mass squeal has moved from 3200rpm, to 2800rpm moderate shift, top end wise, feels like the car has picked up an extra 500rpm, hard to describe, boost punches to 10psi pre laminova's, and that last stage of the rev range where it pushes to 11.5psi feels tough.

Still haven't fitted the headers yet, but they are ready to go. Need a few days off to fabricate the rest of the system.

Have kept the primaries stock s54, into the collectors which are now 2.5 inch.

Thoughts at the moment is to run two 2 1/2 100 cel cats, into a Y, then 3 inch all the way to the muffler, then back to twin 2 1/2 inch out the muffler.

There will be a hot dog in the 3 inch to try and keep a handle on drone.
Dyno time.
Some numbers please.
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Last edited by cosmos328Ci; 05-26-2014 at 06:24 PM.
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Old 05-26-2014, 06:30 PM   #14
Davew
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In the shed as I write this, tig welding exhaust components.
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Old 05-26-2014, 06:43 PM   #15
cosmos328Ci
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Quote:
Originally Posted by Davew View Post
In the shed as I write this, tig welding exhaust components.
Kool.

It will be interesting to see your AFR from your dyno run.

The exhaust should sound great. ***55357;***56840;
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Old 05-26-2014, 07:08 PM   #16
jdjg
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2.5" SS single pipe + headers + Magnaflow + Remus


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Last edited by jdjg; 05-26-2014 at 07:33 PM.
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Old 05-26-2014, 07:23 PM   #17
GuidoK
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Quote:
Originally Posted by Davew View Post
In the shed as I write this, tig welding exhaust components.
you make your own headers? Nice

I've adapted a set of schmiedmann headers/cats. They are originally ment for a e46 328i automatic but are easily adaptible (I have a Z4 so a bit different with the 6 speed) with some small v cuts and tig it up.
They're also sold under different suppliers on ebay
http://www.ebay.com/itm/STAINLESS-SS.../190769008806?
Piping is 2x 60mm or so (2x 2.125" or so))
Headers will make your exhaust sound pretty loud and foremost raspy (you know, the typical inline 6 sound)

The stock exhaust manifolds are really really restrictive
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Old 05-27-2014, 06:13 AM   #18
Davew
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Quote:
Originally Posted by GuidoK View Post
you make your own headers? Nice

I've adapted a set of schmiedmann headers/cats. They are originally ment for a e46 328i automatic but are easily adaptible (I have a Z4 so a bit different with the 6 speed) with some small v cuts and tig it up.
They're also sold under different suppliers on ebay
http://www.ebay.com/itm/STAINLESS-SS.../190769008806?
Piping is 2x 60mm or so (2x 2.125" or so))
Headers will make your exhaust sound pretty loud and foremost raspy (you know, the typical inline 6 sound)

The stock exhaust manifolds are really really restrictive

I bought a set of S54 LHD headers to convert to RHD. Been a long day but they will work well as far as fitment goes
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Old 05-27-2014, 03:13 PM   #19
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Originally Posted by Davew View Post
I bought a set of S54 LHD headersitj to convert to RHD. Been a long day but they will work well as. far as fitment goes
Yes, the port spacing is almost the same, just need to cut the flanges off and oval the ports. (easier if you have standard exhaust ports!)

I have the full M3 exhaust on my compact including the backbox.

It all bolted right up apart from the backbox.

Last edited by zek926; 05-27-2014 at 03:13 PM.
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Old 05-27-2014, 05:56 PM   #20
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Quote:
Originally Posted by zek926 View Post
Yes, the port spacing is almost the same, just need to cut the flanges off and oval the ports. (easier if you have standard exhaust ports!)

I have the full M3 exhaust on my compact including the backbox.

It all bolted right up apart from the backbox.
Was there an increase of pwr & tq?
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