Custom Big Single Turbo upgrade

Dumaurier7

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May 19, 2020
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Hi all! I am aware of the various turbo upgrades and available kits on the market but has anyone attempted a custom kit of their own ?
 

RuskiRacer

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Jul 17, 2019
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2009 e93 335i
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RuskiRacer

Captain
Jul 17, 2019
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2009 e93 335i
There's so many home made turbo kits don't have to try and look to hard
 

RuskiRacer

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Jul 17, 2019
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My Bad!...….This is very true, but they all seem to be the much easier top mount! anyone do a custom Under Mount set-up yet ?
I mean it's probably much easier making the top mount setup . There are people who have made custom bottom mount setups. It's just trickier to fit everyything,clock the turbo, fit a air filter. Much better in my opinion to have access to the turbo and o2 sensors in a more reasonable position if switching to single turbo
 

Dumaurier7

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May 19, 2020
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I mean it's probably much easier making the top mount setup . There are people who have made custom bottom mount setups. It's just trickier to fit everyything,clock the turbo, fit a air filter. Much better in my opinion to have access to the turbo and o2 sensors in a more reasonable position if switching to single turbo
Yes it is MUCH easier because the space under there is very tight due to the lean on the engine, the motor mount, the chassis rail and in my case the steering shaft and Joint! its difficult but it is doable. Although, as you said its easier to access the turbo this was not really a factor for me, since a turbo is something you don't mess with on a regular basis and the sensors were re-positioned to the manifold to allow better access than OEM. The reasons I decided to go undermount are because there are important plastic stuffs located on the top side of the motor which I did not want to risk burning or melting ! the better spool offered by shorter runners and I prefer the "stealth look" as from the factory. I have successfully made my own kit using a tubular SS manifold and a Borg Warner EFR 8474! all that remains is rerouting of the water pump suction and discharge lines ( in progress) along with repositioning of the thermostat, I'll try to post pics later when I get home from work.
 
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RuskiRacer

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Yes it is MUCH easier because the space under there is very tight due to the lean on the engine, the motor mount, the chassis rail and in my case the steering shaft and Joint! its difficult but it is doable. Although, as you said its easier to access the turbo this was not really a factor for me, since a turbo is something you don't mess with on a regular basis and the sensors were re-positioned to the manifold to allow better access than OEM. One of the reasons I decided to go undermount is because of the important plastic stuffs located on the top side of the motor which I did not want to risk burning or melting ! better spool and I prefer the "stealth look" as from the factory. I have successfully made my own kit using a tubular manifold and a Borg Warner EFR 8474! all that remains is rerouting of the water pump suction and discharge lines along with repositioning of the thermostat, I'll try to post pics later when I get home from work.
Very curious to see what you've come up with!
 

Dumaurier7

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May 19, 2020
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The manifold I came up with! I used 1.5” id schedule 40 304L stainless steel for strength and durability.
 

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Dumaurier7

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Turbo and manifold mounted for final fitment checks and adjustments and also for fabrication of the repositioned water pump lines.
 

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Dumaurier7

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BW EFR 8474, turbo smart BOV, Dinan dual core IC, AFE intake , Super Sprint cat less down pipe and full system with Quad exhaust tips, PR stage 2 LPFP ( for now) , PR -6an fuel line upgrade , PR coil upgrade, EOS pump controller, Phoenix Racing intake with 750 cc injectors, SS PI controller, MHD and XHP flashes!
 
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Dumaurier7

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For the future! 7 point Pro Meth WI system with Torque Byte controller, custom LSD , custom Stage4 lpfp upgrade, Crank hub solution, S55 oiling system and SHIT LOADS OF FUN!
 
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RuskiRacer

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Did you go with the efr because there's almost nowhere to mount a waste gate? Also I don't see where you placed you o2 bungs
 

Dumaurier7

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I went with the EFR because I could retain the electric BOV and wastegate actuator, I don’t want any codes! I also chose BW because I never owned ( always been an original Garrett guy) one so I wanted to try something new. I mounted the VTT O2 bungs with the manifold off the car but had to remove them due to not liking their orientation, I plan to mark and remount them now that the manifold is on the motor. After completion everything is going to be thermal and powder coated black for heat control and to give it the stealth factory appearance!
 

Dumaurier7

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Custom fuel pump upgrade to go with the turbo!
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Dumaurier7

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Some bits after coating!

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Dumaurier7

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I have since upgraded to a top mount A2W intercooler set up due to the difficulty of fitting the turbo inlet and outlet pipes in the same space occupied by the thermostat ( on the F22 the thermostat is directly mounted to the radiator) . I went with the Phoenix Racing intercooler, Mishimoto and Frozen Boost heat exchangers.For the pump I am thinking about using The Bosch water pump which I currently have ( from a previous build/ car) but I’m thinking to upgrade to a Davies Craig unit since the Bosch is soo under rated now!
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Dumaurier7

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May 19, 2020
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Wait! what? why? a fancy valve cover and an aluminum intake manifold???!! :tearsofjoy: ........if you say so !
 
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martymil

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Sep 6, 2017
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Everything is custom around the engine enen head and block.

The only thing that's stock is injectors and sensors for now