Buildup: My quest for NA 180 hp

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Boyracer

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Buildup: My quest for NA 180 hp
« Reply #60 on: February 11, 2008, 05:21:04 PM »
Small update...

Bought one black Sparco Corsa seat, I hopefully get it tomorrow but installation is few months away when track season opens here, until that car is driven everyday. I think I will take both front seats away and build mounts for drivers side to mount the seat. That should save some 40 kg of weight, always a good thing :)



I also have 10 m2 roll of of glassfiber fabric arriving soon as well as 3 m2 of carbonfiber fabric. Those are meant for airbox but I think there is enough to manufacture something else too. Sunroof insert or similar.

Oh, and new set of 225/50-16 tires for lightweight track wheels are orderer too. Cannot wait to try out how much better they feel on track compared to those hideously heavy 17" wheels!

Contacted the ebay chip seller about my car to ask what info he needs to produce me a chip. Turns out I'm lucky, my car is produced before 09/94 and he can burn me a chip just like that. Cars produced after that date need their ECU's sent to him so he can create custom chip. I just have to confirm what code the ECU module has and that means I have to remove retrofit A/C units heat exhanceg to get my hand on the module...

He promises around 154 hp at 7100 rpm from stock E36 M42 which is 10% increase with 98 octane fuel (not sure how much that it in US). I will ask him to set the rev limiter to 7500. Our local BMW club is going to have a dynoday or two this spring so I hope to have some hard evidence on this.

It might be that the ITB installation is postponed to mid summer when I can use M3 as everyday car.

bmw318is1994

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Buildup: My quest for NA 180 hp
« Reply #61 on: February 12, 2008, 03:42:55 AM »
this is just simply amazing!  i would like to get around the 170-190HP mark NA I think that'd be effing awesome!

Boyracer

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Buildup: My quest for NA 180 hp
« Reply #62 on: February 19, 2008, 02:32:40 PM »
Yay, got the seat! Sexey! :cool:



Installed front powerflex bushings to control arm and roll bar. Steering feels bit more communicative, small things happening under the front tires are bit easier to feel.



And removed retrofit A/C to see how difficult it would be and to find out exact model of ECU my car has.



Turns out the A/C will be quite easy to remove once the system is emptied, no heat exhanger inside dash. I estimate weight saving to be around 10-15 kg from this. I estimate empty weight of the car will be around 1150 kg at the beginning of the track season.

Chip maker replied with info and prices so I ordered two chips from him:

1. Stock engine 98 octane fuel 7500 rpm limit - 155 hp
2. Shrick camshafts 98 octane fuel 7500 rpm limit - 170 hp

Combined cost with shipping is around 150€.

Boyracer

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Buildup: My quest for NA 180 hp
« Reply #63 on: February 27, 2008, 10:56:03 AM »
Chips were shipped to me yesterday and they should arrive in few days :)

I did buy something interesting today that I had no plans for... Used Wössner forged pistons for S50B30 engine! Price for 6 pistons were well below of set of 4 similar pistons for M42 so I just had to take the opportunity. I can hopefully use 4 on my engine and have 2 as spare :)



As far as I know at the moment, those should be quite compatible with M42. Bit of data I have gathered so far (S50B30 / stock M42):

Code: [Select]

Bore: 86 / 84 mm
Wrist pin: 21 x 59 / 22 x 55 mm
Comp height: 31.6 / 31.6 mm
Compression: [COLOR=Red]12.6[/COLOR] / 10.5


M42 when bored to 86 mm has engine displacement around 1882 cm3. Modest increase itself but benefit I'm interested lies elsewhere...

- Compression ratio should give 2-4% increase in torque and efficiency. Guy who used these pistons on his S50B30 said he had no problems with compression rate as high as that and I see no reason why M42 should be any worse.

- Weight! From Wössner's site:

Piston: 306 g
Wrist pin: 85 g
Rings: 20 g (estimate)
Total: 411 g

Stock M42 piston with rings from ETK: 510 g

Not sure if that includes wrist pin which is around 100 g. So forged piston is atleast 25% lighter, maybe even more. That means less losses and possibility to rev higher because con rod has less mass to control.

- Durability. Because they are forged, they will take lots more revs than standard cast pistons.

- Large valve cutouts. Wössner pistons have room for S50 valves that are larger then stock M42 valves so if I go to oversize valves I do not need to worry about clearances :)

Basically, with these pistons it should be possible to rev far higher then with cast pistons. I really am not an expert but region of 8500 rmp should be well within reach.

There are few problems:

- M42 con rods have 22 mm wrist pin, these pistons have 21 mm wrist pin. I think this can be fixed by changing the bush in con rod small end (anyone know for sure?)

- Bore. I have to rebore the M42 block...

- Balancing the crankshaft. Since pistons etc are different weight, bottom end should be carefully balanced to allow high revs.

I have been looking for forged pistons for some time but this opportunity caucht me by suprise so I have not definite plans or firm knowledge about this area... Lots of things to learn in near future! :cool:
« Last Edit: February 27, 2008, 10:59:49 AM by Boyracer »

tim_s

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Buildup: My quest for NA 180 hp
« Reply #64 on: February 27, 2008, 12:50:56 PM »
The CR won't be 12.5 or whatever in an m42. If they're anything like the pic you've shown it will lower, not raise the CR in an m42.
over 12:1 CR is not going to be usable on pump gas (not that yours will have that high a CR anyway).
pick components to get to your desired CR and dynamic CR, not the other way around

You'll likely weaken the engine more by using oversize SE bushes than the benefit of forged pistons.

what piston-bore clearance will you run? What rings do the pistons come with? Is this supposed to be a road engine that you're building, or solely a race engine?

skimping here is a false economy. You need some pistons designed for your application.
« Last Edit: February 27, 2008, 01:25:26 PM by tim_s »

2.1 200bhp, 175ft/lbs 318is
E46 330ci daily

Boyracer

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Buildup: My quest for NA 180 hp
« Reply #65 on: February 27, 2008, 02:56:47 PM »
Quote from: tim_s;43739
The CR won't be 12.5 or whatever in an m42. If they're anything like the pic you've shown it will lower, not raise the CR in an m42.
over 12:1 CR is not going to be usable on pump gas (not that yours will have that high a CR anyway).


It is entirely possible that it is not as high as 12.6 which is just as well, this is not an racing engine and I do not need last percentage of power.

Engine those pistons are coming from ran fine with 12.6 compression (essentially a stock S50 engine apart from engine management and pistons) with 98 octane pump fuel. Max ignition advance was around 37-40 degrees but that engine had 300 degree cams that lowered dynamic CR somewhat.

Here is pic of one of the exact pistons I should receive. The other one is stock S50B30 piston for comparison.



I think it would be pretty difficult to get lower CR then 10.5 with those if compression height is identical to stock M42 piston.

Quote from: tim_s;43739
pick components to get to your desired CR and dynamic CR, not the other way around


My desired CR is in bracket of 11:1 and 12.5:1. Planned cams are quite mild and with little overlap so static and dynamic CR's are close.

Quote from: tim_s;43739
You'll likely weaken the engine more by using oversize SE bushes than the benefit of forged pistons.


Actually they are UNDERSIZE bushes, stock pin is 22 mm and those pistons come with 21 mm pins. So nothing is weakened by removing material, bushing is just made bit thicker to get the hole diameter smaller.

Quote from: tim_s;43739
what piston-bore clearance will you run? What rings do the pistons come with? Is this supposed to be a road engine that you're building, or solely a race engine?


Clearance will be whatever manufacturer recommends and piston rings will come directly from them too (only 2 rings instead of stock 3 per piston). M42 and S50 iron blocks are quite close relatives so I am quite optimistic instructions for S50 are close for M42 too.

This was going to be road/track car but I am now seriously considering leaving this car for track use only and buying 3rd BMW for winter use. I have some perversion for E36 316i coupe :D

Quote from: tim_s;43739
skimping here is a false economy. You need some pistons designed for your application.


Cheapest new forged pistons I have seen in europe for M42 are 750€ / set. From US they could be obtained bit cheaper but not much. This set I got for far less then half of that 750€ and as a bonus I have 2 spare pistons.

So it is not an large investment and if they do not fit my application for some reason I can sell them forward. Or my friends will get nice ashtrays for christmas presents :D

We had difference of opinion in the past but I appreciate your input, it is good to have someone to challenge your plans :)

Oh yeah, I went to buy digital kichen scale with 1 g accuracy so I can measure things more accurately instead of relying manufacturer information...

tim_s

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Buildup: My quest for NA 180 hp
« Reply #66 on: February 27, 2008, 05:22:30 PM »
basically, you're wrong.
Quote

I think it would be pretty difficult to get lower CR then 10.5 with those if compression height is identical to stock M42 piston.

Measure them. They look like they'll give a respectable CR, but there's lots of dish in those valve reliefs, and sharp edges on those unnecesarily large valve reliefs will mean hot spots and more chance of det. they're not a great choice for your car.
your car has a 10:1 compression ratio, not 10.5:1. I've told you this before. Compression height between the pistons is not identical, it's marginally shorter.

Quote

My desired CR is in bracket of 11:1 and 12.5:1. Planned cams are quite mild and with little overlap so static and dynamic CR's are close.

those figures are miles apart

Quote

Actually they are UNDERSIZE bushes, stock pin is 22 mm and those pistons come with 21 mm pins. So nothing is weakened by removing material, bushing is just made bit thicker to get the hole diameter smaller.

no. the bushes are OVERSIZE. Please learn before contradicting me, you've done this several times before and it's insulting.

as per my original post, just buy the right pistons for the job. Sure pistons that actually fit your car will cost you 375euro extra, what will a rebuild when the small end bushes give out cost you?

2.1 200bhp, 175ft/lbs 318is
E46 330ci daily

Boyracer

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Buildup: My quest for NA 180 hp
« Reply #67 on: February 28, 2008, 04:49:29 AM »
Quote from: tim_s;43760
basically, you're wrong.


Well I'm glad that was cleared out :p

Quote from: tim_s;43760
Measure them. They look like they'll give a respectable CR, but there's lots of dish in those valve reliefs, and sharp edges on those unnecesarily large valve reliefs will mean hot spots and more chance of det. they're not a great choice for your car.


Wössner says on their documentation that piston dome has volume of +5 cm3. Stock piston has depression on center of piston so I would imagine it has negative volume.

I don't think valve reliefs are unneccessarily large, they are very useful for oversize intake valve conversion, 35 mm (M42 33 mm stock) should give no trouble at all since it is very close to OEM S50 size which those pistons surely are able to accomodate. On previous engine those reliefs were more than enough for valve lift of 12,7 mm!

Those are forged pistons as said and they are more dense material than cast pistons so they will generally run cooler. Only really thin and  sharp corners are on edge of piston near valve reliefs but that is not a problem because heat is transferred to bore walls from that area. Wössner pistons have won BMW WTCC and ETCC championships so I am quite optimistic that they know what they are doing :)

Quote from: tim_s;43760
your car has a 10:1 compression ratio, not 10.5:1. I've told you this before. Compression height between the pistons is not identical, it's marginally shorter.


You are actually right, I checked from BMW papers this morning. It's just that most of the internet sources say E36 M42 has CR of 10.5 :eek:

I think lower stock CR of 10:1 and slightly lower compressiong height of forged piston is actually better for me. That means when fitted the static CR will be closer to 12:1 then 12.6:1 which should suit cams with little overlap better because they do not lower dynamic CR that much.

But to be sure I have to measure the combustion chamber/piston dome volumes as you said, too much guesswork right now.

Quote from: tim_s;43760
those figures are miles apart


But does it really matter as long as it works? I am not building an competition engine where every last % counts. I want it to be higher then stock and I do not want it to be too high to cause eccessive retardation of ignition. That's why the bracket is so large.

Compression ratio can be adjusted by machining either piston dome or cylinder head or fitting thicker/thinner head gasket. So there is possibility to adjust it when the design progresses.

Quote from: tim_s;43760
no. the bushes are OVERSIZE. Please learn before contradicting me, you've done this several times before and it's insulting.


If you bore engine to have larger bore diameter is it undersize or oversize? It is oversize.

On this case, inside bore of bushing is made to have smaller diameter. Logically it should be undersize. Or is there some different logic that applies to bushings?

If you feel insulted, then stop reading my posts, or atleast replying to them. Nobody is forcing you...

Quote from: tim_s;43760
as per my original post, just buy the right pistons for the job. Sure pistons that actually fit your car will cost you 375euro extra, what will a rebuild when the small end bushes give out cost you?


Actually 750€ pistons are 450€ more expensive then what I paid from mine. Plus I have 2 as spares.

To fit M42 forged piston I would have to most propably hone the bores anyway so no savings there. With these pistons I atleast get bit of extra displacement (5% or such) and lots of room for larger valves.

Stock M42 con rod small end bush costs 4€. It is simple interference fit to con rod so old one is pressed out and new one is pressed in. Then you have to hone it to have correct clearance with wrist pin. Work should not cost much because it is standard procedure.

Only question mark is to find/manufacture suitable bronze bush to reduce the wrist pin diameter by 1 mm compared to stock :)

I had the choice of having these forged pistons or having no forged pistons at all. The real question here is, are these better then stock cast pistons. And I think they surely are.

tim_s

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« Reply #68 on: February 28, 2008, 07:35:55 AM »
you will be using an undersize pin and an oversize bronze bush. the bush is oversized for the extremely illogical reason that it's bigger. the same applies to everything, regrind your crank -> put in oversize shells. no special logic required, just common sense.

And nothing is weakened? Since when has phosy bronze been as strong as forged steel?

2.1 200bhp, 175ft/lbs 318is
E46 330ci daily

Boyracer

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Buildup: My quest for NA 180 hp
« Reply #69 on: February 28, 2008, 01:34:28 PM »
Quote from: tim_s;43807
you will be using an undersize pin and an oversize bronze bush. the bush is oversized for the extremely illogical reason that it's bigger. the same applies to everything, regrind your crank -> put in oversize shells. no special logic required, just common sense.


Hmmm. Put in that way (oversize bearing shells), it sounds plausible :)

Quote from: tim_s;43807
And nothing is weakened? Since when has phosy bronze been as strong as forged steel?


I think the real question is how much weaker is 0,5 mm thicker bronze bush? It might be bit softer but it's difficult to see how it could fail with catastrophic results. Pin/small end clearance could increase slightly over time but that is not a huge worry compared to snapped con rod.

I did already find out today that over/undersize bushings (well, one with smaller inside diameter anyways) are common practice and re-bushing small ends is cheap and standard procedure.

Next worry is the head gasket. I suppose M42 gasket is not ok for 86 mm bore... Where one can find gasket that is ok?

The two chips I had ordered arrived today, yay! I try to get stock engine baseline rolling road results next week before I fit first chip :)

EDIT: Measured stock piston, rings and wrist pin weight today. Those forged pistons with rings and pin are 15% lighter compared to them.
« Last Edit: February 28, 2008, 01:39:43 PM by Boyracer »

Wise Old Dog

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« Reply #70 on: February 28, 2008, 02:55:54 PM »
M44 gasket is 1mm larger than M42

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« Reply #71 on: February 28, 2008, 03:15:11 PM »
Quote from: Wise Old Dog;43834
M44 gasket is 1mm larger than M42


Do you know if it is direct swap for M42 gasket?

Largest M44 oversize piston is 85.485 mm (mine will be bit less than 86 mm) and I think there is only one OEM head gasket available which then should also be able to accommodate those oversize pistons also.

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« Reply #72 on: February 28, 2008, 04:04:22 PM »
Solved that one! Cometic makes M42 gasket with 86 mm bore :)

86mm MLS .060" C4349-060 1 $141.70

Wise Old Dog

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« Reply #73 on: February 28, 2008, 04:39:40 PM »
Direct fit. We have it on an M42 block bored to 2nd oversize M44 pistons. Fits just fine.

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« Reply #74 on: March 03, 2008, 08:13:47 AM »
Guess which one is stock?

Forged pistons have 32 mm exhaust and 37 mm intake valve cutouts, they are also significantly deeper than on stock piston. No worry about valves hitting pistons with higher lift cams.

They are also 18.5% lighter and offer 5% larger displacement. Their resistance to metal fatigue is far superior.



Cleaned up:



Chips. Claims are +15 hp on stock engine and +30 with mild cams. We shall see how it goes...



I already had spare set of E36 M42 con rods that I am now going to lighten, polish and shot peen.

Now I'm looking for m42 engine block, or better yet, complete engine bottom end for boring. How the heck did this happen? :eek: