Exterior:
HRE C20s 19x9 - 19x10 | Euro Mirrors | 6000K Philips HIDS + Fogs |CSL
Boot Lid & Diffuser
| Euro Bumper Engine / Drivetrain:
BMC Airbox | Stygar CS | Stygar SS | UUC Stage II Lightweight Flyheel + Ceramic
Clutch | UUC Red Tranny Mount |BHS Fan Kit | CSL Ceramic Coated Headers | S-Sec
I | S-Sec II | Kreis-sieg Valvetronic F1 exhaust system Suspension / Brakes:
Alcon 6pot Front - 4pot Rear | Moton Club Sport System |
Ground Control Race Camber Plates | Ground Control Hybrid Front LCAB |
Ground Control Rear Camber Arms | Ground Control Monoball RTAB | Ground
Control Monoball RSM | Ground Control Sways
New Upgrade Build Sheet - items currently being discussed
Engine Externals D/A Level II Supercharger Package (in-house
builds only)
The above package is available now for in-house builds only. Level
II will include complete ported and polished heads and custom ground
D/A cams. Level III will be a complete low compression engine. Both
include the above build sheet.
This project is scheduled to begin the build out in mid February.
D/A currently does not sell S/C bolt on kits, we build one off projects
to suit the clients needs. Cost is determined by factoring parts,
labor, and materials. Each project is different with defined parameters
set by you the client. If you're interested in a custom FI solution
for your E46 M3 please contact us to discuss your goals.
She arrives at the shop
Sorry about the pictures it was getting dark.
Now that this project has been fully defined the time has finally come
to take the next step. This is the let's get dirty and methodically disassemble
her phase. It will be during this process that present systems and pieces
will be inspected and then repaired or replaced as the means to establish
a strong foundation to build upon.
Once everything under the gal was disconnected and removed such as the “Kreis-sieg
F1 Valvetronic” exhaust, the under body panels, heat shields, the driveshaft,
etc. to create a clear shot at the transmission it was then removed in
order to confirm the condition of the recently installed UUC lightweight
flywheel and racing clutch assembly . Mechanically everything looked
fine as such all of the friction surfaces were simply dressed, the T/O
bearing was cleaned and re-lubed, and then the UUC lightweight flywheel
and clutch system and the transmission were reinstalled. We then removed
the previously coated CSL headers in preparation of removing
the head for the next phase of the project to begin. The head will become
a fully “Blue Printed” assembly with extremely close tolerances being
held to. It will receive larger valves and seats, high performance springs
and retainer, full porting and polishing, and real time flow testing
and air flow balancing will be completed during this process.
One of the goals with this gal is to maintain and in fact increase if
possible the very low end torque. The low end torque situation is typically
compromised when LC pistons are used in a supercharging as such a higher
than typical CR will remain which means that intake charge cooling and
the final tuning issues became much more critical. One of the objectives
associated with the head work is to maximize cylinder fill for the benefit
of both the lower end torque (torque likes fuel) as well as being better
able to maintain a controlled combustion environment when operated within
the extreme upper RPM range.
By and large the gal has presented herself well and upon close inspection
it became obvious that many hands have worked on her all for the purpose
of keeping her “Fit as a Fiddle”. There is no doubt that this gal's owner
loves to exercise her and yet it is also blatantly obvious that he also
takes extreme pride and care of her; this is an ownership attribute that
we find most refreshing to see.
Here is what she looked like before the process began
On the lift ready for the project to begin
Underside prior to tear down
The tear down/disassembly underway
The clutch assembly being inspected and then once this was completed
and it checked out fine the assembly was then prepped and made ready to
be reinstalled
The upper header nuts are being attacked from the top side; it is a
bit awkward accessing a few of these
The clutch and transmission back in place
The next phase is to remove the head and perform some magic on it as
a key foundation piece of this gal's supercharging project. As mentioned
above we are having larger valves and seats installed, extreme porting
of the head, and high performance valve springs and retainers are just
a few of the notable mentions that will take place.
With the radiator out it will now be used as the dimensional template
for an extreme radiator to be designed. The head is now finally ready to
be removed.
Here the process of removing the head is well underway
Here the head has been removed and is being made ready for
the machine shop. The next step for the block and pistons will be the methodical
cleaning of everything preparing for the reassembly stage. The head looked
wonderful, no carbon build up in the combustion chamber or on the back
of the valves. The tops of the pistons look perfect, no significant carbon
build up. Internally the engine appears clean, no gum, sludge, etc. “THUMBS
UP”
This is what she looked like before having the pistons and
the block prepped
As the piston and block preparation progressed.
The pistons and the block surface has been prepped awaiting
the thoroughly massaged head to be installed.
Here the head modifications have been completed.
The process included the complete disassembly and a thorough
inspection followed by a complete refurbishing of the head. It was during
this process that larger valves and seats were installed, complete intake
and exhaust porting was completed, custom ground performance cams, springs,
and retainers were installed as well as new followers.
The next phase is to have the head installed
and the “beast” brought back to life in a few days; she has been sleeping
long enough
The reinstallation of the head is underway
The Vanos is being bench prepped before installation
The head is on now it is time for the secondary components
to be installed so that she can be woke up
Here ALCON brake system's massive front 14.5” rotors are
being replaced all as the means to make certain that she will be able to
stop quickly during the many extreme moments of exercising her
Here the Custom Spec'd Race Version T-Trim Supercharger has
been set in place for the first time
Here the gal is being prepared to go back under the knife
Here the “old” (somewhat subjectively speaking) Ground Control
Advanced Design suspension is being removed in favor of the “BAD BOYS” aka
Moton's
Here the “BADBOYS” are being fit into place
at the rear
Here the front is being disassembled once again as with
the rears to removed the ‘old” Ground Control pieces in favor of the “BADBOYS”
The story will continue to unfold so check back soon
Here the Moton's have been installed. The final ride height
and then alignment has yet to be completed. This will be done once all
of the supercharger pieces are in place so that any compensation required
can be taken into consideration
Here the Moton remote reservoir is temporarily placed
out of the way. The remote reservoirs at the front and the rear can not
been permanently at this time because of additional system overlays yet
to be put into place. As can be seen in the picture the fronts they were
simply tucked neatly into the front brake cooling ducts as a interim
place to keep them safe and free from damage and then once the supercharger
system is in place the space available within the engine bay will be
assessed and then the final location/installation will be completed.
The rears are simply temporarily zip tied up and out of the way.
Here her shoes are back on along with the new HRE center
caps pursuant the customer's request.
Here after several months of working with sketches
and cardboard models the creating of the final custom supercharger intake
system is well underway.
There will be pictures presented as the days unfold however for the
moment let it be sufficient to say that aesthetically the systems are
stunning and functionally exactly what the sleeping beast require to
let them breath like "Dragon's"
The two gals have now been moved next to each other so they can proceed
to the next phase of evolution.
Finally this gal is being removed from the shadows
of Area 51 after months of cloaked development work. The process of implementing
all that we have been working on is now commencing.
Here the nose of the gal is being removed for access so
that the supercharger system and all of the secondary components can be
fit into place
Here the nose of the gal has been exposed
Here is the new SuperSprint stepped header
exhaust system being inspected and arranged in preparation of the installation.
The SuperSprint system will run from the heart of the gal through the
stepped headers, the high flow small metal bed cats, the large mid-pipe
with resonator and then finally exit through the awesome sounding Kreis-sieg
F1 valvetronic's muffler system.
To say the system will sound wicked is an understatement and even more
importantly the system will flow and the SuperSprint designed/engineered
extraction qualities will compliment the Vortechs T trim supercharger's
efforts and the Schrick cams operating the head within which a significant
amount of work was done.
From the whine of the T Trim Supercharger to the angry growl of the
Kreis-Sieg exhaust you'll know she's coming and be in awe as she leaves.
This project continues to evolve over time with
one such an example being the exhaust. Initially Twain coated CSL headers
and CSL cats were installed exiting through a non-resonated mid-pipe and
then finally the Kreis-sieg F1 valvetronic muffler system. However after
much debate the decision was made to install SuperSprint's newest stepped
header system along with SuperSprint's small metal bed cats and mid-pipe
with resonator. The system will still exit through the very cool and very
extreme Kreis-a sieg F1 valvetronic muffler system
Here the SuperSprint exhaust system is being installed and
integrated into the Kreis-sieg F1 Valvetronic muffler system
So the owner of one of the Extreme Supercharged M5's came
in from out of town to look at a couple of the projects and at the same
time attempt to convince the owner of this gal to let him take her home
with him. As can be seen in the picture he remains anxiously at bay with
Noah awaiting your reply... his last words were "so, what's up? -philly
Well after much debate
the Alcon's are being removed in favor of Brembo's “BIG DOG” GTR brake system. YES we said Brembo
"GTR" brake system. While there is no doubt that the Alcon's are a wonderful
system however the Brembo GTR brakes are considered the “TOP DOG” system
and then add to this they look awesome against the HRE wheels
Here the process of swapping the Alcon brakes for the Brembo's
is well under way
Here the rear brakes are being bled before being able to
call this phase a wrap.
Here the rear Brembo GTR brakes have been installed
Here the Brembo GTR brakes have been made ready to install
on the front of the gal
Here the Brembo front rotor has been installed
Here the “Bad Boy” GTR Brembo brakes have been installed
on the front of the gal
Here the Brembo brakes can be seen through the HRE wheels;
SWEET !!
Here is the custom aluminum radiator designed
specifically for our supercharged E46 gal. Up close and personal it is
a stunning piece to look at and then add to this mechanically it was well
thought out. The installation is as OEM and even uses all OEM hardware.
Both of the primary radiator hoses are OEM BMW however the upper hose is
from an E36 M3. It has a full radiator shroud as well as pressure relief
vents designed and fabricated into it. This unit will insure that the gal
remains happy being exercised even during the extreme heat of a typical
summer's day.
Here the back side of the gal is being buttoned up; in
this picture the new style Kreis-sieg F1 Valvetronic's exhaust diverter
valve has been installed and the final plumbing is underway. During this
phase the rear Moton shock remote canisters are being installed with
access to them within the boot/trunk area.
In addition to this the custom charge cooler
aka "Ice Box" has been completed and all fitting was confirmed. We
are presently installing the last of the detail pieces to it which include
the by-pass valve mount plate and the physical underside support brace.
Once this is completed it will be installed for the last time and then
the associated plumbing can be completed. We have also devised a rather
cool custom mounting setup for this gal's front Moton shock remote
canisters. The primary pieces for this are presently being machined with
final installation expected later in the week.
Here the process of mounting the rear Moton remote reservoirs
is underway. You can see that we created service access for the system
to be fed through and once completed we will fabricate a removable service
panel to seal the area and to allow for the ease of service as the years
roll by.
One of the considerations during the selecting of the Moton
canister placement was access and because this gal ride so long to the
ground the idea of installing them under the gal simply was not an option
Now that the Moton system has been installed it can be easily
and quickly adjusted by doing nothing more than opening the boot and lifting
the floor carpet access panel
In addition; all of the OEM tools and accessories will remain
in their original location however we still need to create clearance for
the Moton gas lines as they will be run/located under the hard OEM Styrofoam
insert.
H ere is the little custom aluminum access panel that will
allow for future service
Here the OEM Styrofoam tool tray insert was modified so
as to maintain proper clearance for the Moton remote canister hoses that
are now located under it and to retain an OEM appearance once installed
Here the system is being installed for the last time
Here the project is completed appearing as if it could
have been OEM this way
Here the front Moton shock remote canisters are being mounted
in such a way as to compliment the gals' racer looking engine bay and to
allow for very easy dampening adjustments.
The center sleeve is custom fabricated specifically for this client
and is one of the many detailed items included for this gal.
Here the OEM grills are about to be removed for a much more
stealthy look befitting of this gal' new personality
Here are the fully blacked out grills installed which presents
her with a much more aggressive and business appearing nose
Here the OEM under the hood pad is being removed to make
room for the custom cut Mylar panels soon to be installed.
The Mylar panels will brighten the engine bay, reduce even
more than the OEM pad the thermal/radiant heat transfer into the hood and
add a more of a racer appearance when displaying the gal with her bonnet
open for all to see the mechanical eye candy.
Here the OEM under the hood pad has been removed and patterns
are being created so that Mylar inserts can be installed. The Mylar inserts
offer much greater heat reflection and also brighten up the engine bay
making it look simply awesome
Here the Mylar inserts have been installed and the final
detail work is being completed
Here the Chrome trimmed OEM side vents have been replaced
with the stealthy all black versions. This added to the now all black
front grills gives this gal an even meaner attitude.
Here the gal's front fascia is being trimmed and then fitted
with the custom heat exchanger grill. During this the process the heat
exchanger will be installed for the last time as we continue to tend to
some detail items as we await a key component of the intake system from
the composite team
Here the custom machined aluminum collar is being fit
in the upper portion of custom carbon fiber intake tube. This collar
allows for good sealing and eliminates damage to the carbon fiber tube
at the clamping area
This shows the ID difference between the typical Vortech
S trim versus this gal's T trim supercharger inlet
Here the custom machine collar has been bonded into position
using a special Hysol mix spec'd for this application. Now all that needs
to be done is the cleanup work around the edges however since we still
need to bond the by-pass bung into position we will wait until that has
been completed
Here the completed custom upper carbon fiber intake tube
has been fit into place so as to verify for the last time the location
of the soon to be installed by-pass bung
As with most motor-heads
we like “HOT” gal's
and consider our cars as one. The thing that we do not want is uncontrolled
extreme heat within her engine bay as such we created a custom Halon
fire suppression system for this project. The pictures below will
show the process as it is unfolding. We are now in the exciting final
assemble stage with this gal which is the time that all of the cool
twist and tweaks are able to be installed. The Halon system will
react automatically if the need is detected and leaves no residual
throughout the engine bay such as conventional fire extinguishers
do.
Here is the custom machined bracket designed to properly
locate and secure the automatic fire suppression systems discharge nozzle
Here the custom machined bracket and the automatic fire
suppression discharge nozzle have been set into position so that the final
hose length and placement can be determined
Here the upper portion of the custom carbon fiber intake
tube has been fit with the custom machined by-pass bung
Here the pass-pass hose has been trimmed and fit into position
Here the custom upper radiator hose setup is being completed
Here is the Kreis Sieg exhaust switch that allows the
gal to either migrate through town barely noticed or at the flip of the
switch roar like a wild beast being rudely awoken
So here we go with the final phase of integrating
all that was previously dry fit as we move this gal closer to the tarmac.
In addition we will be completing the fabrication of the wiring harnesses
and integrating secondary systems such as the custom automatic fire suppression
system and the Zeitronix's system for real time data logging.
Now as a brief recap; the goal for this project from day one was fairly
typical; to increase the gal's performance while systematically integrating
numerous secondary systems such as the Moton remote reservoir shocks,
the extreme Brembo brakes, AquaMist water injection, dual speed electric
fan. All this was to be completed in a very clean OEM appearing manner
while maintaining the ease of service however, there was a final requirement
attached to this project which would forever set this gal apart from
the pack.
The final requirement was that the integration needed to be done in
such a manner that it did not resemble the path that others before her
had taken.
It is as the result of the final requirement that a clean sheet of paper
became the basis of defining this project. As stated; we approached every
detail as if no one had been down this path before as such the intercooler
system, the by-pass system, the idle control system, the water injection,
the fire suppression system, the strut bar, the manner in which we integrated
the custom secondary wiring harnesses, the plumbing of the intercooler
system and the gal's heart, the integration of the Moton shock system
and the placement of the remote reservoirs are a just a few of the key
elements that are unique to this gal. The closer one looks the more they
will see; she is akin to an automotive eye candy store.
Here the secondary wiring which included numerous relays
and fuses is being integrated into the passenger side firewall compartment.
In addition the DME compartment had the Zeitronix's system integrated
as well as the boost MAP sensor. During the wiring process we created
junction points for the 12 volt constant, 12 volt switched, and ground
similar to that which is done by OEM on both the driver and passenger
side of the gal so that future service and integration of additional
items can be completed with ease.
Here the custom automatic fire suppression system is being
integrated into the gal. The goal was to make the system appear as though
it could have been on the gal from day one as such we ran the stainless
steel Halon suppressant feed line along side of the fuel and vacuum rails.
Here the intercooler pump is being integrated and plumbed
Here the AquaMist water injection pump is being neatly integrated
into one of the few available spaces that remain on this gal; it was at
this point that 1/16" measurements became our friend.
Here is one of the cool little custom stainless steel pieces
fabricated; this one is the vacuum manifold for the various secondary systems.
Many elect to use simply plastic tee however they do do weather the test
of time and furthermore most OEM's would not use them.
Here is just one example of the custom wiring harness that
we fabricated for this gal. This particular one is for the intercooler
pump. We use only full wrap OEM style sheathing and then the ends are all
sealed to insure a long and trouble free service life; wiring is one of
the many items that once integrated should never have to be dealt with
again.
Here the intercooler plumbing is being fabricated and
integrated. We used stainless steel tubing and then change the tubing
diameter in a couple places as the means to create the pressure and flow
we desired throughout the intercooler system. We did this rather than
use in line restrictors which would have been much easier. You can also
see that the Tig welding process used when integrating alternate size
stainless steel tubing is very detail orientated.
Here the charge cooler has been fully assembled and is being
integrated into the gal's engine bay.
Here you can see the custom bumper closure panels installed.
As you can see we used the backside of these panels as the place to mount
the HID ballast for the lower running lights.
Here the mounting system for the custom D/A Streamline air
filer is being completed. We installed Nutserts into the bracket mounting
panel rather than use a simple nut and bolt method so as to make future
servicing much easier.
Here the truly custom license plate frame is being installed
along with a current set of tags as such I would say that she is very close
to being exercised.
Here she is full of fluid; wet as I like to say ready
to have the battery connected and then let her start breathing hard
Now that she has been presented in all her
glory with every project requirement met it's time to bring her to life.
In this video the front bumper cover remained off so we could bring her
up to operating temperature and confirm that all systems function as
designed and that we had no leaks etc. The initial run was not only successful
but was glitch free. Next we will install the bumper cover, the gal's
front wheels and then we can exercise her during which time we will be
data logging her vitals as we finalize the tuning process before she
has her day in the lights with the magazine folks and then she will be
traveling home to her Papa.
One more walk-around
Here she is calmly at idle yet when tapped snaps to attention
Here you can see the data logger being set up before her
first road trip for the first round of live tuning
And so as with all of our projects, its a sad day for us
and a joyous one for her owner. Soon she will be tearing up the roads in
Boston.
Alien Technology Forced Induction Programs Phases I
& II are now available. Please email us for more information. We
would be happy to discuss your project.
*D/A will not bubble wrap a blower and ship it to you for DIY. Each
project is customized to reach the clients goals.
