Jake's Epic BMW 135i Build Thread! (5+ Years of Ownership)

[Daggerty]

Is this going to be pure e85 then? What's the fuel setup going to be?

[Daggerty]

[patsbimmer1]

Daggerty said:

Not in an N54.  The stock internals are rock solid.  North of 600whp on these cars isn't unusual for stock internals.  The only guys looking for upgraded internals are aiming north of 900whp which I don't think has happened yet.

[suspenceful]

Daggerty said:

Is this going to be pure e85 then? What's the fuel setup going to be?

Yes. Adding six 750cc injectors with a sandwich plate between the head and intake manifold (still with direct injection). Two Walbro 450 pumps going in the fuel tank bucket. I should be able to run full E85 at all times.

As far as the high boost on stock internals... it's always a roll of the dice. Some stock N54s hold 850+whp no problem. Others blow up with stock turbos. 700whp will be pushing the envelope but with proper parts, tune and maintenance, I should be okay. Alas, I am on WIBimmers so I'll need all the luck I can get.

[GunMetalGrey]

suspenceful said:

Alas, I am on WIBimmers so I'll need all the luck I can get.

Best of luck good sir!

[Bassboy3313]

​

[suspenceful]

Tonight's sunset was incredible.

[B C]

middle photo is neat, I like the blurry grass that is barely visible

[Jdesign]

Dang!!!!  Another lovely photo-set. (BUT WHERE ARE THE BURNOUT VIDEOS?!?!?!?!)

[suspenceful]

I tackled the fueling upgrades this weekend (upgraded fuel feed line not pictured).

First step was to install my new Precision Raceworks Stage 3+ fuel pump bucket that had two Walbro 450s stuffed inside. Robert at PR was nice enough to assemble this for me. Usually you have to modify your stock bucket while mounting and wiring up the pumps yourself.

After fiddling around in the gas tank for a bit, I got the stock bucket out. New PR Stage 3 bucket on the left, old bucket on the right (with my old Stage 1 inline pump attached).

Installation was basically reverse of disassembly. Fairly straightforward, more gas on the hands. A plug-and-play harness is included in the kit to activate the 2nd pump under boost. I routed it from the battery to the two new terminals on the top of the bucket, then up under the hood to a Hobb's switch that I plumbed into my charge pipe. The 2nd pump is set to kick on anytime I'm over 15PSI.

Next up was installing the port injection and upgraded fuel line. I reconnected the battery right before this to test that the LPFP bucket installation worked as it should. For those of you who are aren't familiar with these cars, they run/prime the fuel pump every time a door opens after the car is "asleep". Well, I disconnected the OEM fuel feed line and then opened the door so I could route the upgraded line to the tank. As soon as I opened the door, the pump kicked on and fuel went spraying everywhere out of the open port. I'd assume a gallon of gas was on the garage floor before I quickly plugged the OEM line back in.

Battery disconnected, OEM fuel line out, new fuel line plugged in.

I ran the larger fuel feed line up to the front of the car and started removing parts so I could install the port injection.

Intake manifold removed, port injection plate installed. I added a dab of gasket sealer to the o-rings just to make sure they stayed on.

I connected the upgraded fuel lines to the HPFP and port injection plate. Then I connected all of the injectors to my BMS port injection controller and spent an hour wiring that up to my ECU. I managed to fit everything in the DME box for a stealthy installation. Everything went back together smoothly and you can't even tell the port injection is in there unless you look for it.

After everything was back together, I connected the battery and went to test that the port injection worked. As soon as I did, the fuel pumps primed and I heard fuel spraying under the car. Not just a small leak, it was dumping fuel - another gallon or two on the floor. I quickly disconnected the battery and investigated.

Well, my dumb ass forgot to plug this port on the plate! The kit comes supplied with a proper plug and o-ring... make sure to use it!

I wrapped things up and went out for my first full tank of pure E85. No more mixing!

The car pulls strong on 28PSI, stay tuned for more updates!

[Jdesign]

Hell yes!! I want a ride in this thing!

Did you have to pull the whole intake manifold back off when you realized you forgot that plug on the end of the secondary fuel rail?

[B C]

Congrats on not dying from the fuel hazards, also congrats on not dying from whatever power level you are at [emoji1319]

[suspenceful]

Jdesign said:

Hell yes!! I want a ride in this thing!

Did you have to pull the whole intake manifold back off when you realized you forgot that plug on the end of the secondary fuel rail?

I hope to have it at that meet this fall, maybe then!

And no, I didn't. Luckily I was able to snake my hand back there and tighten it.

Snap said:

Congrats on not dying from the fuel hazards, also congrats on not dying from whatever power level you are at

Thanks! I'd like to strap it on the dyno sometime in September.

[REKIII]

Very cool system.  Is it a returnless?  Maybe a better way to ask this, is the car returnless stock?  if so, does this add a return line?

[suspenceful]

REKIII said:

Very cool system.  Is it a returnless?  Maybe a better way to ask this, is the car returnless stock?  if so, does this add a return line?

These cars come stock with a returnless fuel system. I didn't add a regulator or return line with this upgrade, that's the next level up as seen here.

[REKIII]

suspenceful said:

These cars come stock with a returnless fuel system. I didn't add a regulator or return line with this upgrade, that's the next level up as seen here.

OK, makes sense.  I wonder how they plumb the return line in.  It's been something I've been scratching my head on with mine for awhile.

[suspenceful]

My new intercooler came in last week and I was able to tackle the job yesterday. Let's first compare intercoolers. Stock vs. VRSF 7" vs. VRSF 7.5" Race intercooler.

Definitely larger and definitely heavier. Let's take a closer look at the fin density and cooling bar size.

Old intercooler:

New intercooler:

Much better  now let's get this thing in the car!

It required A LOT of cutting and trimming.

I thought this would be enough, but I was wrong. I had to cut even more before I could stuff this intercooler up in there.

Now that it's in, does it blend work?

My previous intercooler saw a 54° rise in intake temperature during a 28psi 60-130mph pull. The new intercooler only rose 5° during a similar pull with similar ambient temp. See light blue line on my logs.

Before:

After:

Overall, very happy with the results! One step closer to hauling ass.

[m42b32]

Wow that's a huge improvement!

[patsbimmer1]

That's the first time i've seen a pick of one installed or compared to the 7" and OEM.  That's fucking massive!  Did you happen to check your coolant temps before and after to see if they were affected negatively from this?

[B C]

Holy toast! Thanks for posting the before and after info, very fascinating!