BMW 335i Single Turbo Kit Coming Soon!!!February 9, 2012, by Mike B
The car is alive and well. We partnered with Vishnu in the development on this kit. Thus far Shiv has begun tuning and datalogging and the intial results have been good. Stay tuned as we further develop this exciting project.
The 335i we used to develop this kit already had a decent amount of upgrades performed including; ASR modified factory turbos, Vishnu methanol injection kit, Helix Front mount intercooler, a Spec clutch and flywheel, and a Vishnu PROcede to name a few.
*This turbo system is patent pending.
The factory twins are located low in the engine bay, hardly visible from this view.
The Helix front mount intercooler is visible only to the trained eye behind the grill. This is great for vehicles located in California and the strict emission standards enforced here.
In order to remove the factory twin turbo system, the front subframe must be lowered to gain access to the mounting hardware.
It's a very tight fit in the engine bay. The rear turbo has already been removed. Placement of the new turbocharger is key to ensure there are no oiling or fitment issues. If the turbo is mounted too low, the oil will not drain properly and the car will smoke.
Constant adjustments and revisions of the turbo system requires the removal of the engine from the car during the design phase. This allows easy access to areas of the engine where the turbo system will be residing, expediting the development process.
The stock twin turbos found a new home in the garbage.
The future home of the VFFSTS.
After designing the manifold the fabrication process can begin. Pictured below are the collectors and first two runners tacked to the cylinder head flange. Tack welding each piece prior to final welding to ensures proper fitment.
We've lowered the car down around the manifold and turbo to double check clearance with the frame rail. Sure enough, we have plenty of space as we follow the timeless mantra, "measure twice, cut once". Below are two more angles of the manifold as they will sit in the engine bay.
We're test fitting the upper runners in this photo below. We've left the engine in the engine bay. This is to ensure proper fitment and clearance before welding the runners in place.
The primary and secondary collector sections of the manifold have been finalized. The bends on this manifold are very intricate, and are designed to be as close to equal length as possible, ensuring. The car has been lifted up again, and we're adjusting the mounting position of the turbo to make sure the intercooler piping fits up nicely.
The manifold is as close to equal length as we can get. The blue tape on the turbo is protecting the turbo from getting any dust or metal shavings in the oil passages. We've seen countless failures caused by ignoring small details such as this.
After test fitting, the manifold was again removed then weld it all together. The primaries have already been welded together. Below are some photos of the primary runners being welded.
Our experienced fabricator welding sections the manifold. Our manifolds are all built and fabricated in house for quality control purposes. We back purge all of our manifolds to ensure strength, long life, and have been on some of the fastest Mitsubishi Lancer Evolutions in the state for years without failure.
Here is a close up view of the runners after they've been welded. Each manifold is assembled by hand by our team of experienced fabricators.
When making a manifold, some of the runners have to be removed from the flange, welded together, and then put back. (You can see the RWB Porsche 964 we built for SEMA 2011 in the background here. Click here for more incormation on that build. )
After completing the manifold, we designed a jig to ease replication. The same high quality fit and finish can be reproduced consistently with this set up.
I managed to get some photos of the VFFSTS from beneath the car as well. We managed to get all of the wastegate plumbing and downpipe to fit around the factory engine mounts. No modification of the subframe is necessary to install this turbo system.
In this slightly different angle, the wastegate flex joint is visible. We chose to recirculate this wastegate to minimize noise.
All flanges and adapter are CNC cut including the adapter made to route the water pipe around the turbo system. Heat barrier tape is placed on the adapter as well as on the frame rail to protect from heat.
Pictured below is the Y section of the downpipe which mate to most popular exhaust systems.
The twin intake pipes are eliminated and one single filter is placed on the inlet of the turbocharger.
Another view of the revised charge pipe.
The factory oferflow bottle stays in its stock location.
The PROcede controlls the fuel injection and ignition timing while working in conjunction with the factory DME. One lambda sensor per bank allows all the safety features of the factory DME to remain in place. Keeping both lambda sensors dedicated to each bank keeps closer tabs on the air fuel ratios. Instead of having one sensor moniter the average of six cylinders, we have the advantage of taking the average of three cylinders instead.
This view of the entire engine bay shows just how clean fit and finish is with the VFFSTS installed. Most people may not even know how much performance is hidden beneath the hood of this 335i.