Forced Induction Superchargers | Turbochargers | Intercoolers

TC78 BMW build

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Old Dec 15, 2012 | 07:19 PM
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Default TC78 BMW build

After wrecking my supercharged LS1 BMW 325i, I decided to move up to a 5 series. The downside is the car is around 600 lbs heavier... With more weight, comes the need of more power.

The old homemade setup using an Eaton m112 off of a Ford Lightning.



The new car



The engine in.



Then this stuff came in





The setup will be

Turbonetics TC78
All stainless hot side
Homemade manifolds to keep a/c
PTE 46mm wastegate

Turbo placement



Manifolds
Schedule 10 304 stainless. 1.5" and 2" OD




Pulled the motor today after marking the oil pan to notch it some so it will clear the steering rack a little more.



Manifolds an motor, tacking 2.25" v bands on.




Mocking up the cross over pipe
2.25" stainless 16 gauge pipe



And that's where I left off this evening.

I have seen some people use a flex joint in cross overs. What do you guys think?
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Old Dec 15, 2012 | 07:26 PM
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looks great. Awsome looking car. year????
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Old Dec 15, 2012 | 07:29 PM
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It's a 99 528i
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Old Dec 15, 2012 | 07:35 PM
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Great job with the pipe!
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Old Dec 15, 2012 | 07:57 PM
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Very nice! Are you changing the rear axle?
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Old Dec 15, 2012 | 08:01 PM
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This is going to turn out to be an insane car when its done.. Im watching this build
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Old Dec 24, 2012 | 04:02 PM
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putting a flex in the crossover will make it easier when u go to put it back together after welding.just make sure to use a good flex section.
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Old Dec 24, 2012 | 06:19 PM
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This is gonna be a great build.
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Old Dec 24, 2012 | 06:29 PM
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An unbelievably clean build so far!
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Old Dec 25, 2012 | 02:49 PM
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where did you order your manifold tubing?
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Old Dec 30, 2012 | 07:30 PM
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acestainless
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Old Jan 2, 2013 | 07:41 PM
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sweet build. Nice fab work. in for results.
Kory
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Old Feb 15, 2013 | 12:08 PM
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Had to modify the drivers side motor mount to allow the downpipe to go through it.






Wastegate placement




New crossover pipe



Some new scrap aluminum



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Old Feb 15, 2013 | 02:05 PM
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Your serpentine belt is going to hate you. Cool motor mount idea though.
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Old Feb 17, 2013 | 05:56 PM
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Here is the final finish on the manifolds. I'm not a fan of shiny things under the hood so I decided to sand blast them then go over them by hand with a scotch-brite pad.




One last full mock up to check some clearances.




Next on my list was to make a little more room for the 4" intake. I cut the "frame rail" and notched it, then welded in a new section.





Also made some brackets for the aluminum radiator the utilizes the stock radiator mounts. More on that later.
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Old Feb 17, 2013 | 06:05 PM
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hopefully ur not running an open wastegate.. thats gonna make the engine bay messy. other than that awesome job man.
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Old Feb 17, 2013 | 06:13 PM
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Nope, will be riunnng a 2" pipe back into the exhaust. Still need to make a notch in the inner fender to make some room for that.
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Old Feb 17, 2013 | 06:23 PM
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Originally Posted by 357i
Nope, will be riunnng a 2" pipe back into the exhaust. Still need to make a notch in the inner fender to make some room for that.
good good. i looked at the clearance and thought "That is gonna make a mess if he doesnt recirculate that lol..."
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Old Feb 17, 2013 | 06:59 PM
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Wow, nice change of pace. I remember when you did the supercharger build. I like this alot. Good work. Thats def an interesting and unique way to do the turbo. Kick *** for doing something different.
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Old Feb 23, 2013 | 07:45 PM
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Added a -4 turbo feed fitting to the oil cooler adapter


Here is the notch I had to put in the oil pan. The welds aren't great due to the aluminum being cast and oil saturated...but it's sealed fo sho.



Here is the pan on, turbo feed and drain in place


Lastly I started wiring the motor up. I plan to fire the engine very soon!
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