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Go Back   E46Fanatics > Tuning & Tech > Driveline, Engine & DME Tuning

Driveline, Engine & DME Tuning
Talk about driveline improvements, NA tuning and DME tuning your E46 BMW here. This includes diffs, intakes, exhausts, chips, software and OBD tuning.

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Old 10-06-2012, 05:28 PM   #1
IrocThe325i
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Thinking about building a custom intake mani.

soooo im probably gonna pick up a used intake manifold and make a custom aluminum sheet metal intake.

anybody have one laying around they wanna donate???

also do you know if I can code out the sensors for the disa and such computer controlled gadgetry on the intake manifold with an AA tune???

and i know. I'm probably gonna end up losing power from doing this but i have such a burning hatred for this silly ugly plastic manifold.

hopefully ill have it made and installed by spring if all works out. Main issue will be the computer side of it.
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Old 10-06-2012, 05:55 PM   #2
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hard to believe i can't find an aftermarket intake manifold for m54s...
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Old 10-07-2012, 11:20 AM   #3
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bump. interested in this
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Old 10-07-2012, 11:30 AM   #4
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I'm curious why you're doing this.

If it's mostly for looks, I'd just muse that there might be some advantages to the plastic one we have. Also, getting it waterproof seems like it'd throw some curves your way with fabrication.

Also, wouldn't aluminum transfer a lot of heat into it that the plastic probably insulates the intake from (a tad)?

Could I maybe interest you in something from our ICV or TB cleaning department instead?

Edited: I thought you meant air filter housing at first...now I'm even more curious why you'd want to do this.
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Old 10-07-2012, 12:05 PM   #5
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It's definitely possible to make an "equal length" manifold. But you're going to need to do a lot more work than just a new mani. The throttle body, and all intake equipment will need to be repositioned.
Something kinda like the m3 intake manifold.
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Old 10-07-2012, 12:39 PM   #6
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It's definitely possible to make an "equal length" manifold. But you're going to need to do a lot more work than just a new mani. The throttle body, and all intake equipment will need to be repositioned.
Something kinda like the m3 intake manifold.
i assumed the ICV is built into the throttle body? If so there's no reason the throttle body which i believe is just a four bolt square mount can't be relocated to another location. The DISA can be removed as long as the computer will accommodate such a mod. The PCV can be changed because thats as simple as a vacuum vent for the crankcase.

Fuel rail and injectors can also be replaced with aftermarket ones if i choose to do so.

Im going to attempt to keep the runner lengths near stock length and have a plenum that is nearly the size of the motor.

honestly as r*cey as this sounds its going to be more for just something unique and cool rather than performance... like a cold air intake, since we all know those hardly increase performance.

Damn BMW makes everything so efficient.
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Old 10-07-2012, 12:56 PM   #7
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So is it purely for look or performance? Because if it's performance, what are you using for your airflow model?

The honest truth is there isn't anything to be gained changing the intake manifold because the head flows so poorly as it is. Spend time on that, and leave the manifold alone.
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Old 10-07-2012, 02:03 PM   #8
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So is it purely for look or performance? Because if it's performance, what are you using for your airflow model?

The honest truth is there isn't anything to be gained changing the intake manifold because the head flows so poorly as it is. Spend time on that, and leave the manifold alone.
i was hoping ud pop in!

its more for looks. i hate the plastic one.

im looking to pick up a head to have built but its gonna be a 3-4,000 dollar project and im not sure its worth it on a 2.5.

i rather put it towards an s54 swap


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Old 10-07-2012, 02:26 PM   #9
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I'm sorry, OP, but now that I understand it's the intake mani you want to build, I'm thinking it'd be headache after headache...and then more headaches when you get to the computer stuff. There are so many ports...things that need to be bolted on, to say nothing of the accuracy you'd need to get the intake tubes to fit exactly where they need to fit and fit tight.

Maybe you could just make a nice aluminum cover for it and be satisfied.

Please don't take this post as a challenge to push you to do it either. It sounds crazy, even assuming you have all the skills and tools to do this...which I assume you do.
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Old 10-07-2012, 02:59 PM   #10
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my friend works at a race car fabrication shop. He can have a flange cnc'd to fit the head. Then its just a matter of making six runners to match the port on the flange and gradually shape into a circle which will have a velocity stack attached inside of the plenum. Plenums the easiest part. Where the runners go in it will be a flat piece of aluminum and then the rest will be shaped either round or oval idk thats for my fabricating friend to decide. Then the flange for the throttle body also to be machined.

the hardest part will be where the fuel injectors seat in, i have no idea what the seat looks like.

that and figuring out what to do with the excess vacuum lines and such.
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Old 10-07-2012, 03:35 PM   #11
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i was hoping ud pop in!

its more for looks. i hate the plastic one.

im looking to pick up a head to have built but its gonna be a 3-4,000 dollar project and im not sure its worth it on a 2.5.

i rather put it towards an s54 swap


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I had my head redone on my old 2.5 ported and polished with new custom valve guides, cause they didn't make Standard size valve guides, he flow benched it before and after and it picked up 85% more flow over stock. And it only cost $1400. I also added cams and springs. Total was 3200 installed. I could have done it my self and it would have only cost about 2100

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Old 10-07-2012, 04:05 PM   #12
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I had my head redone on my old 2.5 ported and polished with new custom valve guides, cause they didn't make Standard size valve guides, he flow benched it before and after and it picked up 85% more flow over stock. And it only cost $1400. I also added cams and springs. Total was 3200 installed. I could have done it my self and it would have only cost about 2100

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Power gain?
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Old 10-07-2012, 04:16 PM   #13
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284.2rwhp, and 297.7rwtq, I'm trying to find my dyno paper now.

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Old 10-07-2012, 04:21 PM   #14
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soooo im probably gonna pick up a used intake manifold and make a custom aluminum sheet metal intake.

anybody have one laying around they wanna donate???

also do you know if I can code out the sensors for the disa and such computer controlled gadgetry on the intake manifold with an AA tune???

and i know. I'm probably gonna end up losing power from doing this but i have such a burning hatred for this silly ugly plastic manifold.

hopefully ill have it made and installed by spring if all works out. Main issue will be the computer side of it.
I'm also trying to do the same thing but in stead of aluminum I'm going to make it out of aluminum pieces and make molds and make a final one out of carbon fiber, that should make more power and hold in less heat. But I'm trying to do this on a 3.0l cause i swapped my 2.5 for it.

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Old 10-07-2012, 05:59 PM   #15
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284.2rwhp, and 297.7rwtq, I'm trying to find my dyno paper now.

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Um... You had 284rwhp after a port and polish? Are you kidding?
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Old 10-07-2012, 06:02 PM   #16
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Um... You had 284rwhp after a port and polish? Are you kidding?
Cams too, high compression pistons 11.5:1 that's why i am looking for my dyno results paper.

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Old 10-07-2012, 06:03 PM   #17
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Um... You had 284rwhp after a port and polish? Are you kidding?
He also had cams installed. I assume high lift/duration cams and custom tuning done. Still have no idea how he made S54 power for $3000 without boost.
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Old 10-07-2012, 06:07 PM   #18
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He also had cams installed. I assume high lift/duration cams and custom tuning done. Still have no idea how he made S54 power for $3000 without boost.
Yes 272 shrick cams and it took a lot of crunching numbers with my Machinist...i mean allot.... Almost 2 months.

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Old 10-07-2012, 06:10 PM   #19
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But that motor is toast now, but anyway i would like to see how he makes this intake mani, i am trying to incorporate the disa tho.

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Old 10-07-2012, 08:43 PM   #20
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He added like 80% power without boost.
There's no way.
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