[OpenFlash]

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UPDATE. Now making 627WHP
NEW DYNO RESULTS HERE: http://www.e90post.com/forums/showthread.php?t=651949


Original dyno/info thread: http://www.e90post.com/forums/showthread.php?t=646950

Hi guys,
The last few days have been a bit hectic. We did the following maintenance work to our 82,000 mile old test car:

1) Intake valve cleaning (walnut shell blasting at dealership)
2) New DME harness (original one was a mess from 6 years of development/testing).
3) New rear o2 sensors (Universal Bosch sensors @ 75/each)
4) New spark plugs (previous ones were 10,000 miles old)
5) New fuel injectors (replacing the originals which had 82,000 miles of use)

The last item, in particular, made a huge difference. For some reason, the production date of our car (03/06) made it ineligible for the big fuel injector recall last year. But recently I started noticing a miss during very light load at 2500-3000rpm. Not bad enough to trigger any codes but bad enough to notice if you paid attention. This also caused fuel adaptions on bank 1 to get wacky, racketing up to 22% at times. The tech at the dealer was surprised to see original injectors on such a high mileage car, suggesting that they all go bad by 60k miles. So i went ahead and replaced all the injectors earlier this morning. And what a difference it made! The car drove much smoother and the light throttle hiccups were gone! The car felt more powerful as well which meant it was time to go back to the dyno (Dynojet at DNR Performance, Hayward CA).

And she did well! Especially considering that the current Procede firmware limits boost to a maximum of 20psi. Over the next few days, we'll raise this value to 23psi (limit of stock MAP sensor). But even at 20psi, the old girl made a whopping 585whp. And now that the Procede is controlling boost so nicely, I implemented an gradually upward sloping boost curve. The relatively low boost target at 4000rpm resulted in minimal driveline stress and surprisingly good traction on the street. And the gradually upward sloping boost from then up to 6000rpm kept the torque curve nice and flat which got us the big power number. With a simple firmware revision (with higher max allowable boost), we should keep this ramping up to 6800rpm (21-21.5psi) which should give us the 600whp we are after. But that is not for another few days.

Some dyno runs from tonight:


Datalog of Run #5:


Video of Run #5 (run starts at the 35 second mark):

Some observations:

1) Our Procede-controlled upgrade fuel system is working well. This upgrade does no involve additional injectors. Nor crazy amounts of methanol injection. With it in its current state of tune, there are no signs of nearby fuel system limitation. Fuel rail pressure is spot on as well (see datalog). Clearly, any claims of the DI system having injector on-time limitations is unfounded as well. As are claims of the factory DME code bottlenecks. Funny how quickly misinformation spreads.

2) The stock cylinder head flows well! We are making nearly 17hp per psi of absolute pressure. That is rocking! Much better than an FBO car running stock turbos at max efficiency at just 5psi. So much for the naysayers

3) The reasonable low boost pressures in the midrange makes the car far less octane sensitive than running 20psi from 4000rpm on up. This is probably why we are getting away with running just 93oct plus meth.

4) Compared to upgraded twin turbos (RB/ASR) set-ups running the same 20psi of boost, this single turbo system:
- Makes another ~80-100whp up top.
- Doesn't smoke out the tailpipe
- Doesn't fill up the catch can with any oil
- Doesn't whine/whistle/howl
- Does having any wastegate rattle
- Sounds a hell of a lot better with no low end exhaust drone
- Isn't nearly as octane sensitive which means larger margin of safety even at higher power levels.
- Feels heaps "happier" and offers faster boost response above 4000rpm (which is where you would want to be if your having fun anyway).
- Isn't misfire prone AT ALL. Not even once.
- Runs a less aggressive ignition advance curve

This upcoming week, we should have the Procede firmware revised to allow up to 23psi of max boost. Although we should only need 21-21.5psi to make our goal of 600whp.

And after that, we target 700whp!

Exciting times for N54 tuning. It's about time these engines made some serious power!

Cheers,
Shiv

[skinrock]

Simply amazing. Congrats!

[idrift4wd]

make your goal 1000RWHP!

jk Sickkkk. Great numbers! Will this work for automatic gearboxs?

1st 10 second 335i?

[Sigma 3]

I cant say enough about your work that on this. Thanks for pushing the limits on this platform.

[OpenFlash]

Thanks guys... Sean@FFTEC and I took some video earlier tonight of us doing 60-140mph pulls in Mexico. They will be uploaded tomorrow. Our giggling commentary is almost as amusing as the car's rate of acceleration

[G.I.Joe]

Awesome, great news. This will kick some serious a** on the track/strip

[creaminz]

Congrats Shiv. Simply amazing. 600rwhp should br piece of cake at this point. Well done!

[asian010]

Originally Posted by shiv@vishnu

Thanks guys... Sean@FFTEC and I took some video earlier tonight of us doing 60-140mph pulls in Mexico. They will be uploaded tomorrow. Our giggling commentary is almost as amusing as the car's rate of acceleration

...

[Dmacc]

Amazing work it goes to show your dedication when you're posting threads at 2 in the morning on saturday morning

[soulja620]

beautiful guys, congrats...

Do you foresee this kit being offered in an External Wastegate fashion? outta curiousity..

I love the sound =)

[Aridk]

Wow congrats 600 whp "just" around the corner
I´ve been here since start of the N54 and you´ve realy taken it far, if my memory serves me right you´re the first to crack 300 and 400 whp and now shortly 600whp Damnnnn

[OpenFlash]

Originally Posted by idrift4wd

make your goal 1000RWHP!

jk Sickkkk. Great numbers! Will this work for automatic gearboxs?

1st 10 second 335i?

Our next two in-house single turbo conversions are 6ATs. So we will know soon enough. But I expect it to work quite nicely.

And yes, this car should run 10s quite easily. But safety regulations at Sac raceway require a cage if you run lower than a 11.50. I could probably just sneak one 10s pass and then get kicked off the track I suppose. Maybe soon...

Originally Posted by Aridk

Wow congrats 600 whp "just" around the corner
I´ve been here since start of the N54 and you´ve realy taken it far, if my memory serves me right you´re the first to crack 300 and 400 whp and now shortly 600whp Damnnnn

Thanks! We cracked the 500whp barrier first too

Originally Posted by soulja620

beautiful guys, congrats...

Do you foresee this kit being offered in an External Wastegate fashion? outta curiousity..

I love the sound =)

If that is what some people want, we can certainly provide an external wastegate dump. Easy to do.

Shiv

[per]

Great work Shiw, more power than my ESS VT-625 and probably to a much better price, looking forward to see you race a VT-625 at the event

Here is my dyno for comparence

[hotrod182]

It seems like the M3s need a whole lot more Dyno HP to run with lesser HP 335i BMWs at the strip in the qtr mile. I mean, I haven't seen any 500whp M3's come close to the times posted by 480 whp 335i BMWs. This is based on the ESS M3 I timed on the Vbox, and other times I have seen. I think the highest HP M3s are barely cracking 132mph, where a 600rwhp 335i should exceed that easily.

At 600rwhp, I think the single turbo 335i will give those 700rwhp M3s a run for their money. Perhaps it is the huge torque advantage.

Any 60-130 vbox numbers acquired during those 60-140 runs?

[SIKH335]

Simply amazing Shiv. Fftec big congrats for teaming up with Vishnu. This affirms that Vishnu and team are pioneers when it comes to the N54, with a world of firsts. Great job you all should be very proud. Can't wait for the next two 6AT beta cars

[FrankiE90]

20psi - wow
about sec and some change build'n boost to 20psi.
the torque between 3.5 to 4.5rpm! snap ur neck-
consistent 450ft/lbs tq not to shabby.
-gawd dayum - looks fun to drive.

[Irishace]

Really awesome work Shiv, its getting really exciting around here. I am now really seriously looking at keeping my car and not going to p-car route. This is really incredible. It also looks like the car is outperforming your HP calculator too.

[BlackBB6]

Originally Posted by shiv@vishnu

The reasonable low boost pressures in the midrange makes the car far less octane sensitive than running 20psi from 4000rpm on up. This is probably why we are getting away with running just 93oct plus meth.

Again, great work, i'm sure it was an exciting night for you guys.

Anxiously waiting that 60-130 time and video

[D3oneO]

Originally Posted by shiv@vishnu

Hi guys,


3) The reasonable low boost pressures in the midrange makes the car far less octane sensitive than running 20psi from 4000rpm on up. This is probably why we are getting away with running just 93oct plus meth.


Cheers,
Shiv

Just to confirm...these runs were made with meth? If so, what size nozzle and what kinda of mixture? Good job BTW

[dzenno]

CONGRATSSSSSSS! Holy crap that's beastly!!! F*cked Up!

I'm a believer! Lol

Happily handing over ANY current records I've collected

[pentaxis]

Fantastic Shiv! Simply fantastic.

[BES335xi]

Great work! Truly amazing!!!