•   David Gerhardt reacted to this post about 2 years ago
    DARREN’S E82 DRIFTER / 118d / #BMW-E82 / #BMW-118d / #BMW-118d-E82 / #BMW / #BMW-118d-Tuned / #BMW-1-Series / #BMW-1-Series-E82 / #BMW-118d-Tuned-E82 / #BMW-1-Series-Coupe / #BMW-1-Series-Coupe-E82 / #BMW-118d-Rebuild / #BMW-118d-Drift-Car

    Recently we have been working on the turbo front pipe and wastegates. It’s not been an easy task and I’m unsure if anyone else has been able to make a 3.5” front pipe fit in N54 E82? Never mind a RHD one! There is zero room on this side of the engine bay and I now understand why people who make manifolds choose a smaller diameter pipe, but why would we make this easy for ourselves?!

    We were short on room and there was no way we could fit the front pipe in the engine bay without doing something, so we had to notch the chassis leg to make a little bit more room. Some people may frown upon this but it doesn’t bother me in the slightest; it’s still structurally sound and we used a section of 4” pipe for the notch and it worked out perfectly to fit the front pipe in.

    Once we got it past the chassis leg we still had to get it around the manifold and engine mount; it took a bit of time to suss out which way was best, also bearing in mind the flow aspect. Most of the bends are made up of small sections of straight pipe and pieced together as part of a lobster tail and doing it this way we could get the bends perfect. The second 40mm wastegate is now in place as well, which just leaves the screamer pipes to complete, which I’ll be doing very soon.

    We have now managed to get the exhaust all tack welded together and once we get time it will be Tig welded and covered in heat-proof wrap; to be honest the exhaust manifold has seemed to take forever and I’ll be glad to see the back of it but it was a must to get it complete so we can move forward with the build.

    Once the manifold and front pipe are complete, we are going to concentrate on completing the front panel. We have decided it’s best to do a hybrid between the stock front panel and a steeltubed front end, this way we can house all the coolers and charge cooling equipment but keep the stock mounting points for the front bumper and headlight brackets etc.

    We have taken a huge decision to remove all the direct port injection and stock management from the N54 and some may ask why? I just feel like we have the skills to make an inlet manifold and use ‘conventional’ injection that allows us to remove the high pressure pump (which everyone seems to have issues with) and all the DPI and stock management. This will allow us to use a stand-alone management system and no restrictions when it comes to tuning the engine. It’s possible it could be a bad move but I can’t find anyone that has done this yet, so it’s a bit of a stab in the dark. So, next on the list, weld the manifold, build a front panel and make a custom inlet manifold. Thanks to Pete for his time and effort helping me with build.

    Turbo front pipe required a notch in the chassis leg.

    Wastegates now in position.
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