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Old 09-19-2013, 11:26 PM   #1
aflatau
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Custom Top Mount PT6466(335i)

Hey Guys,

New to these parts, I am a user on e90post and a few other forums. So I thought I would come on over here and share with you guys my custom single turbo 335i. I have an 07 e90, and started modding it earlier last year with the basics, come the start of this season I went FBO with a big e85 mix and dyno'd at 480/520.

So I thought to my self why not go single..



There is a quick pic of my car, and this is how I started my process.

When I first start doing research I had quite a few questions I had for my self that I went out and found the answers to share with you guys:


What turbo should I go with?

This was my first issue I needed to over come, I originally wanted todo a custom twin setup - such as GT2832rs but my fabricator said it would be a lot more costly to go that route and a pain in the ass and suggested a single setup.

From there I was concerned about boost lag, I am so use to the powerband of the current OEM twins. So I did some research and found the following turbos:


Garret GTX3582r
Comp CT4 6465 Billet
PT6466

While looking trough all these options I found that the best bang for buck would be the PT6466 for the power goals I want to go with. Problem with this turbo is that it is the most lagy out of the three. But at the end of the day I decided to purchase this option. I purchased the Vband inlet and outlet housings to make a simple install and remove process. I purchased the turbo via maxiumpsi.


Do I run an external or internal wastegate?

I was concerned about which wastegate to run, due to the fact that our OEM system is an internally wastegated setup. I dug around and sent some emails to Terry and found out that an external wastegate is not an issue and to go that route.



Upgrading the BAR Map Sensor?

Since the OEM Bar Map sensor is only a 2.0 bar, and I plan on running more then 20 PSI on this single turbo, I had to find a suitable Bar map sensor. Luckly
BMS offers a plug and play harness for the N20 3.5 bar map sensor. I purchased the map sensor from ECS Tunning and ordered the harness from BMS.


O2 Sensor Placement pre-turbo?


So with going single I have learned that you have to place the O2 sensors before the turbo, when typically you would do post placement. The reason for this is that our OEM ECU reads two separate banks, 1-3 and 4-6 for A/F ratios. If you put the O2 sensors post turbo with a single turbo it mixes the gases and throws off the A/F ratios which will cause a tuning night mare.


What fueling am I going to run?

Well since I have an upgrade LPFP with the Walbro Intake option, I will be running a big e85 mix of atleast 70/30 and move up from there if the system can take it. I want to see what I can do with just e85 around. Hoping to reach 25-26 PSI on E85 alone, but at this point its all hopes and dreams.




What tuning platform?

Well with the new option of open flashing, I will be running the JB4 G5 with the open flash to tune this project. This is where I will see needing the most help from Terry, I will be making a new thread on this alone about this topic.



Here are a few pics of the parts / process.






Test fitment:




Fabrication process:





My goal is to break the current WHP record right now which is 738, and break the 1/4 time which is 10.8 @ 132 well at least the trap.

I have a local tuner / fabricator doing the job for me, He himself has built a 1000+whp e36 a couple years ago, named John Donovan.
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Old 09-20-2013, 01:47 AM   #2
Twin_Turbo_S54
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nice Project, it will be a blast to drive.

which ECU / rods / pistons will you use??
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Old 09-20-2013, 01:52 AM   #3
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nice Project, it will be a blast to drive.

which ECU / rods / pistons will you use??
OEM ECU w a piggy back to control boost and flash to adjust everything else.

Stock internals. The record right now is all on stock internals as far as rods / pistons.
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Old 09-20-2013, 02:29 AM   #4
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Best of luck! Others' doubt and disbelief in something feasibly possible is a fuel to make things happen...I hope you are happy in the end.
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Old 09-20-2013, 08:46 AM   #5
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Damn I love where this is going and I can tell you aren't worried about the naysayers keep us updated best of luck
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Old 09-20-2013, 08:47 AM   #6
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I want a top mount in my e46
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Old 09-20-2013, 03:16 PM   #7
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Good work on the top-mount! I had a 60 trim turbo on top of my e46, but had issues with fitting a normal sized air filter, and extra heat. Where did your fabricater/you get the exhaust flange from? Now I don't fully know the n54s parts 100% but isn't there an issue you may have to address with the high pressure fuel injectors?
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Old 09-21-2013, 04:37 PM   #8
Twin_Turbo_S54
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I want a top mount in my e46

I dont recommend top mount unless there is no location to put a turbo.

My twin turbo S54, where the t***305;p turbo radiates heat causes brittle plastics....

Low mount, heat does not affect the underhood components.
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Old 09-23-2013, 02:16 PM   #9
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Welding is just about completed on the manifold.



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Old 09-23-2013, 03:16 PM   #10
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very nice. are you waiting to test fit before installing the o2 bungs?
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Old 09-23-2013, 03:28 PM   #11
aflatau
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very nice. are you waiting to test fit before installing the o2 bungs?

Yes.
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Old 09-23-2013, 04:40 PM   #12
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smooth runners, beautiful maniifold.

waiting forward for your progress.
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Old 09-23-2013, 04:44 PM   #13
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Old 09-23-2013, 07:31 PM   #14
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This sounds good.
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Old 09-24-2013, 02:53 AM   #15
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Very nice. If i were you i would do a headwork at this point. IIRC N54's head couldn't flow much .

Last edited by Soorena; 09-24-2013 at 02:55 AM.
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Old 09-24-2013, 02:55 PM   #16
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Manifold is completed

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Old 09-27-2013, 08:24 PM   #17
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Downpipe is now in progress.

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Old 09-28-2013, 02:34 PM   #18
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Impressive... cant wait to see the numbers
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Old 09-28-2013, 03:27 PM   #19
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Keep up the good work and post all the news.
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Old 10-07-2013, 02:42 AM   #20
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Well I haven't updated this thread in awhile, but the car is done now. Currently only running 8 lbs off the wategate till I hit the dyno.

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