|
Here I have highlighted the steps to which this vehicle was supercharged.
STAGE 1
This conversion Rand for horsepower is unbeatable. If you were impressed with a supercharged M3 conversion, then read on about this M3.The engine output is rocketed to a fantastic 232 kW as opposed to the factory spec of 210kw. The torque is increased to 355nm as opposed to the stock standard 340nm.
This conversion consists of a new exhaust system which is designed from light weight stainless steel which no longer houses the catalytic converters and will be a full system, although still conservative, one would note the grunt of this upgraded straight six engine. This did not include the manifold.
The Induction system
The standard air filter and air boxes are removed and replaced with two 550bph BMC air filters, which together can flow suitably for 1200bph. These air filters are in-cased in aluminum housings, which separate any hot air, which is trapped under the bonnet.
The air is then drawn from the new location, which is from the front bumper/ spoiler area. High quality 116mm aluminum intake ducts allows the air to be forced into the engine through two distribution tubes situated in the back of the bumper. All very neatly fitted.
Engine electronics
The engine was remapped through the piggyback system, as well as, the fuel changed to leaded, very interesting how we managed to map both the fuel and the timing, As the car has a very very sophisticated engine management system.
Although the engine rev limiter was not shifted, the road speed governor was removed, ideal for us to enjoy the 280+ km mark.
STAGE 2
Having such success of our stage 1 conversion, we had gone even further. this stage 2 conversion added even more grunt.The engine output was rocketed to a fantastic around 255kw as opposed to the factory specification of 210kw. The torque is increased to 390nm as opposed to the stock standard 340nm.
This conversion consisted of the same exhaust previously used in the stage 1. That was the exhaust system in dual 63mm stainless steel big bore tubing as well as stainless steel high flow performance silencers. The tail pipes are crafted to look original but you will distinctively notice they are of bigger diameter. The exhaust manifold in the standard form are found to be exceptionally restrictive so we have designed branch type manifolds that are made from high quality mild steel tubing and then ceramic coated to ensure no rusting or weathering. These manifolds work like a dream adding a great deal more power.
The Induction System
The standard air filter and air boxes were removed and replaced with two 550bph BMC air filters, which together can flow suitably for 1200bph. These air filters are in-cased in aluminum housings, which separate any hot air, which is trapped under the bonnet.
The air is then drawn from the new location, which is from the front bumper/ spoiler area. High quality 116mm aluminum intake ducts allows the air to be forced into the engine through two distribution tubes situated in the back of the bumper. All very neatly fitted.
Engine Electronics
The engine was remapped through the piggyback system, as well as, the fuel changed to leaded, very interesting how we managed to map both the fuel and the timing, as the car has a very very sophisticated engine management system.
Although the engine rev limiter was not shifted, the road speed governor was removed, ideal for us to enjoy the 300+ km mark.
STAGE 3 - SUPERCHARGER
We were then offered the supercharged conversion. All development was now complete and manufacturing had begun. Engine output was rocketed to a fantastic 390kw and maximum torque of 660nm.
This conversion did require decompression, thus the motor needed to be opened.Compression was lowered to 8.5:1 by means of a decompression plate. the lower end of the engine was not opened because the vehicle had fairly low mileage(83000km).
The plenum chamber on the underside was heat treated, by means of an insulated material to help keep boost temperatures as low as possible.
Assembly commences with the main supercharger bracket in place secured with high quality nuts and bolts.
All brackets and pulleys as well as all other fastening devices were either hard anodized, black anodized or powder coated.
Supercharger drive was done by means of a new crankshaft pulley that replaced the original and is designed to suit. The Gates Kevlar Ten rib belt was used and with this set up slippage is absolutely minimal and boost was changed from 0.95 bar boost to 1.2 bar boost at sea level.
The conversion utilised a specially designed Vortech supercharger for the application, with the V2 gear set (quiet operation).We however had the more powerful T-trim supercharger installed and not the SC-trim unit. The unit is oil cooled and oil lubricated with gravitational oil to sump return.
Great care was taken to avoid that retrofit look and thus breather pipes are ally encased.
A Vortech maxi-flow discharged valve was used in order to eliminate any light throttle pulsing or surging.
Original factory long life spark plugs were replaced with racing NGK spark plugs which are two plug ranges colder and freely available from authorised outlets and are changed at fewer intervals alongside recommended engine oil changes.
A high flow large (that's no lie) volume intercooler was fitted to the front of the car. This fits in behind the current mesh and fills the total area dropping boost temperatures to well below the safety limits. All intercooler pipes were made from stainless steel with high polished finish. Intercooler and pipes are joined by means of high quality silicone couplings and once again stainless steel clamps were used.
The exhaust system is uniquely manufactured from lightweight stainless steel, which would no longer house the catalytic converters and would be a full performance system. Although still conservative, one would note the grunt of this upgraded M3 engine. Four exhaust outlet tail pipes are fitted and positioned the same as standard but one can distinctly notice the increase in diameter.
A totally new stainless steel exhaust system is fitted and is manufactured from 63mm duel large bore tubing. Although the system was a free flowing exhaust system it was still very conservative allowing only the sound of this mammoth conversion with the straight 6 note and no boom or annoying sound at any engine rpm.
Exhaust manifolds were removed and replaced with high flow branch type manifolds that are ceramic coated.
The use of factory approved Castrol RS full synthetic oil was employed for conservation of supercharger and other components. A high volume air filter was situated behind the left fog light and is easily accessed for cleaning on service intervals.
We were then offered the supercharged conversion. All development was now complete and manufacturing has begun. Engine output is 410kw (550bhp) and maximum torque of 668nm.
This conversion does not require decompression, thus the motor does not need opening! Standard compression of 11:1 is maintained.
Although the engine is not opened, the plenum chamber as well as cooling system is removed for assembly purposes.
The plenum chamber on the underside is heat treated, by means of an insulated material to help keep boost temperatures as low as possible.
Assembly commences with the main supercharger bracket in place secured with high quality nuts and bolts.
All brackets and pulleys as well as all other fastening devices are either hard anodized, black anodized or powder coated.
Supercharger drive is done by means of a new crankshaft pulley that replaces the original and is designed to suit. The Gates Kevlar Ten rib belt is used and with this set up slippage is absolutely minimal and boost is maintained at 0.5bar at sea level.
All components were CAD (Computer Aided Design) designed and manufactured from the highest quality of alley (b51) and other high quality materials.
The conversion utilised a specially designed Vortech supercharger for our own application, with the V2 gear set (quiet operation). we however, used the more powerful T-trim unit rather than the SC-trim unit.The unit was oil cooled and oil lubricated with gravitational oil to sump return.
Great care was taken to avoid that retrofit look and thus breather pipes are ally encased.
A Vortech maxi-flow discharged valve is used in order to eliminate any light throttle pulsing or surging.
Original factory long life spark plugs are replaced with racing NGK spark plugs which are two plug ranges colder and freely available from authorised outlets and are changed at fewer intervals alongside recommended engine oil changes.
A high flow large (that's no lie) volume intercooler is fitted to the front of the car. This fitted in behind the current mesh and fills the total area dropping boost temperatures to well below the safety limits. All intercooler pipes were made from stainless steel with high polished finish. Intercooler and pipes are joined by means of high quality silicone couplings and once again stainless steel clamps are used.
While the vehicle was being electronically programmed, it was our option to have the fuel changed to leaded fuel. This is purely cosmetic, having for grey coloured tail pipes as opposed to black generated from unleaded fuel.
A boost-enriching regulator was fitted in the left sill behind the left wheel arch. All new fuel lines are made from Teflon braided lines. The reason for this position was,trust me; there was no more space under the bonnet especially on the front and left side. The engine is remapped (programmed) by means of a unichip as well as the road speed govenor removed. This conversion is capable of approximately 328kmh.
The exhaust system was uniquely manufactured from lightweight stainless steel, which would no longer house the catalytic converters and will be a full performance system. Although still conservative, one would note the grunt of this upgraded M3 engine.Four exhaust outlet tail pipes are fitted and positioned the same as standard but one can distinctly notice the increase in diameter.
A totally new stainless steel exhaust system was fitted and was manufactured from 63mm duel large bore tubing.
Although the system is a free flowing exhaust system it is still very conservative allowing only the sound of this mammoth conversion with the M3 note and no boom or annoying sound at any engine rpm.
Exhaust manifolds were removed and replaced with high flow branch type manifolds that are ceramic coated.
The use of factory approved Castrol RS full synthetic oil is employed for conservation of supercharger and other components. A high volume air filter is situated behind the left fog light and is easily accessed for cleaning on service intervals.
Directly behind the kidney grills is an additional oil cooler which sole purpose is to provide additional oil cooling to the supercharger unit. All oil feed lines are manufactured from braided Teflon.
All components were well clear of any body part or the bonnet and are extremely compact.
The entire conversion took about 4 weeks to complete and was done by Rob Green Motorsport In Johannesburg.
The Cost of the conversion was R102000.
We then had the breaking system,clutch and supension upgraded,which is highly recommended with a supercharged vehicle.
We only upgraded the front brakes as the rear is more than adequate after so much more brake increase in the front has been added.
AP racing light weight six pot calipers were used.
AP racing 14inch (355mm) slotted brake discs x 32mm vented.
Billet alluminium, gold colour anodized drive bells. These were designed in-house and carried unique features. These also added a high-tech cosmetic look through the wide M wheels.
Billet alluminium, gold colour anodized anchor brackets
Teflon braided brake lines
AP racing brake fluid
Carbon metallic brake pads.
We then had a six speed gearbox conversion done,which basically used all Bmw components, the only modification was that the propshaft was shortened and balanced.
We also had the famous H&R racing suspension installed.
The entire conversion cost in the region of R180000.
We then brought the vehicle to Pietermaritzburg were we had done further conversions,all under the nose of a Bmw M3!
We then had the unchip removed, thus preventing piggybacking.We had a ECU chip installed which added about much much more power to this M3.The vehicle dynoed at 437kw and 691 Nm torque.
This is an M3 to be spoken about and we have managed a 12,018 second 1/4 mile @ 213kph at Tarlton International Raceway (we have a certificate to prove it).If you ever happen to see this M3 in your rear view mirror on the highway, move over boy, unless you have an Italian sports car!
There are very few M3's on the market that top this M3, one being the once fastest M3 in S.A owned by Rob Green and the other being the 500kw beemer screamer "SMOOTH-ZN" owned by O'b of Chiplogic.
|
