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Old 04-04-2007, 11:37 PM   #1
Nik@vf-engineering
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E46 M3 Supercharger - Anatomy of a VF kit.



Anatomy of a VF-Engineering E46 M3 supercharger system.
VF spent 3 years perfecting their stage 1 supercharger system for the E46 M3 (compatible with 6spd/SMG and all countries). "Was it worth it ?" - asks VF's head of R&D of himself.

"Maybe we went a little overboard on the amount of time we spent in choosing and testing materials. We were meticulous in trying to make the water cooling system as simple as possible. Simplicity meant less to go wrong. The fewer parts, the easier it would be for Do-It-Yourself enthusiast installations. Despite going to a level of perfectionism we have never gone to before with hardware, the software took even longer. The aim of GIAC's key Development Engineer and CEO was to achieve a level of quality never seen before - basically the car should idle, part throttle, full throttle and decelerate with stock-like drive-ability, only except with a lot more power. All features of the ECU were retained including fuel trimming. Using our contacts at Bosch and Siemens we have involved higher flow OEM components to replace the M3's OEM components. We feel we have created a product that will open your eyes. The VF demo car will be featured on the cover of European Car Magazine in a month or two with a no-holds barred review from Les Bidrawn - the editor."

Back to the question: "As means of ensuring that we tested on a variety of models, we installed and tested vehicles brought in from the East Coast and with both transmissions. The overall time invested into the R&D amounted well into the mid-$200K mark which put this project on the verge of being financially in-feasible. However looking back, considering the results we have achieved, I believe it was a risk worth taking. There were many occassions when our energy levels were depleted and goals were challenged but the added motivation from a large following of enthusiasts kept the flames going. The completion of the E46 M3 stage 1 system represents the addition of yet another kit to VF's list of heavy hitter forced induction systems alongside the Porsche 996 and 997S."

Launched just 1 month ago, VF have already sold close to 50 units. The Vortech Engineering V2 SC trim unit is utilized in combination with air/water intercooling aka "chargecooling" to produce astounding results for this boost level. Tuned by GIAC on 91 octane this kit typically produces a gain of 125 rwp with just 5.5 psi. as tested with stock headers, exhaust and clutch on over 12 test cars belonging to independent customers. Results can vary.



- Supercharger unit from Vortech Engineering. Spec Vortech V2SCSQ. Mounted to VF-Engineering 6061-T6 billet (machined inhouse on CNC production line) bracket with bolting pattern. Chrome-moly support bracket with stainless hardware and OEM BMW idler pullies.
- Crosslink custom molded plastic ducting (flow bench tested for anti-air turbulence and molded on in-house rotational modling production line).
- Bosch high velocity and flow water pump with fused relay wiring, Good Year formed hoses with Oettiker and Norma OEM clamps.
- Bosch OEM spray pattern matched - direct drop in replacement high capacity fuel injectors.
- BMW OEM replacement top radiator hose with OEM quick connect.
- Bosch OEM MAF housing.
- Porsche OEM water radiator and frame.
- Crosslink custom molded plastic 2.5 gal water tank (manufactured in house) with powder coated mounting brackets.
- Powder coated wrinkle finish air/water heat exchanger replacement intake plenum (aka manifold). Manufactured by a leading heat exchanger specialist.
- GIAC flash programmed ECU/DME "platinum level" software.


The Software component of this product (despite not being tangible) is very much a major element. Our drivers spent hours at night conducting "desert runs" communicating with GIAC and collecting ECU data at speeds we cannot disclose, often refilling gas more than once on the same day. They often followed routes used by BMW NA's test team in the "Grapevine" region just north of Los Angeles. Known for its very long steady and steep inclines and altitude changes, we were able to test our software in a multitude of conditions. GIAC's engineers put in countless hours of intensive software development in their ECU lab and on their 4wd Mustang dyno. The end result: 400whp on just 5.5 psi on 91 octane with stock cats.

OEM front water radiator as mounted, for that subtle appearance.


Cars that were at VF for long term testing.


http://www.vf-engineering.com
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Old 04-06-2007, 12:51 PM   #2
bavarianx
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Great work on a great kit Nik. We carry only the VF line because of their attention to detail. I have seen how much time and effort they have put into their kits to make them the best product on the market. Time spent in R&D pays off in a big way for the consumer, in a kit that is comprehsive and dependable, not to mention a blast to drive.
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Old 04-06-2007, 06:00 PM   #3
Jlevi SW
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Quote:
Originally Posted by bavarianx View Post
Great work on a great kit Nik. We carry only the VF line because of their attention to detail. I have seen how much time and effort they have put into their kits to make them the best product on the market. Time spent in R&D pays off in a big way for the consumer, in a kit that is comprehsive and dependable, not to mention a blast to drive.
Couldn't have said it better myself. I saw the quality of work VF was doing on VW's Audi's and Porsches, and immediately decided to send them my car

Nik, Do you need this reposted on Bimmerfest? ///M Forum?
JL
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