Even engineers will debate this subject for hours on end lol. I have done it before, I can show 2 co-workers a picture of exhaust A vs. B and ask which one will make more power. I can walk away, come back 20 minutes later and they are still arm wrestling about who is right LOL.

Ask Sam how many hours we have debated exhaust theory, way more than he cares to admit. Sam is a saint man to put up with me lol.

 

I enjoy our debats pal. We both walk away with something from it and you are a pleasure to work with. The fact that you are going back to our "silver bullet" exhaust system and I know your car will do it all makes me more proud of it. You are gonna be happy with the results all around!

 

Coming together nicely!! Looking great!

 

I was comparing data today back to my stock turbos. Very noticeable difference in vane position. As I mentioned in a previous post on this thread, my stock compressor stages were in choke a good portion of the engine speed engine. The new compressors definitely have plenty more room. At similar boost pressures the car is faster because pumping work is down so I'm gaining power on better bsfc. I should have some data to post soon.

Still on 93oct hoping to switch to e85 as soon as possible In the meantime working with Sam to make the 93oct calibration as nice as possible.

BTW zero performance loss from BBi to Kline at this power level. I'm guessing I'm moving around 580-600whp at the moment. I did gain the sound I wanted back

 

Ended up plotting some early data while calibrating the 93oct file using the Virtual Dyno software I used last year to compare the gains of the 63.5mm vtg upgrade. Used the same settings, same road, and all the data is in SAE format.

The first plot is the 63.5mm VTGs on 93oct, Sam is still dialing in the car in the 5.5krpm thru 6.5krpm range. We would expect that area to smooth out. Hopefully we will have the 93oct file done soon because I really want to move on to E85 .

The second plot was an average of how the car ran last year on the stock turbos with 93oct and E85. Most of the gains here are in the reduction of pumping work. Since the larger compressors are not in choke the vanes run more open. Less pumping work, less residual EGR, and better BSFC.

Third plot is vane position just to help illustrate the difference in position at similar boost pressures.

Don't get too caught up in the absolute number and supposedly what power the car is putting down. I personally use the Virtual Dyno more as a comparison tool. Many articles out there on this tool, it can be very accurate when used correctly.

 

Great status M3!! These are great info

 

I use my Cobb datalogging feature, vane position comes in as turbo duty cycle. You will see bank 1 and bank 2. I just use bank 1 for consistency, you can also average both sides, just be consistent. I'm assuming you can pull the same channel through the Durametric, I don't personally know as I have never used it.

Ideally I would have way more instrumentation, in industry the engine would look like Medusa but we are doing what we can with what we have lol.

For example the vanes running more open are a pseudo measurement for the improvement of compressor efficiency at this airflow. It also tells us we dropped engine delta pressure (pumping work), etc..

 

We found a good spot to leave the 93oct tune at. In the chart below you will see the blue data was the first one I shared and the red data was the final. That red data was generated after 3 back to back pulls with no cool down and uphill. I wasn't trying to beat up the engine but I wanted to get enough data to see the consistency of the performance. The torque curve is broad and smooth, peak power (within 95%) is held for ~2k rpms which is nice. The tune has conservative timing, fuel, etc. We aren't trying to break records or parts here. This is my daily driver when the weather cooperates. I'm pretty happy with this level of performance on 93oct .

A couple other comments. Know the limitation of your data collection or analysis tools. The virtual dyno software doesn't have an uphill correction factor . So I'm plotting the lowest reading though all 3 reading are within 600-630whp. I'm planning on ordering a Vbox soon for further performance comparisons . From what I have read on here sounds like the Sport version is popular?

The other comment is quite honestly I have had such a great experience with Sam and his team that's its hard to not mention it every time I post. I know Sam is the face of ByDesign but I think it should be mentioned Sam is connected to some of the best in industry to get you the right product including tuning. No matter how much I bust his ***** on stuff his customer service is awesome. I believe he does care that his customers are happy which is rare in most market segments today lets be honest. I'm not going bash other shops but I have not had the same experience, very clear difference. My 2 cents, take it for what it is worth. That's been my experience.

So whats next? E85 (actually E70 here year round) and ordering the Vbox for fun. I think I'm done in the performance area...maybe

 

Quick update, finally started running E70 and make datalogs for Sam as the tune gets tweaked. Still some work left on the tune but its coming along. Here was a quick snap shot of the virtual dyno numbers. I plan to overlay a bunch of data at the end to show the progression in power over time with the different setups. I'll have more to post soon as we dial in the calibration.

 

very nice results Maestro. As I mentioned in the other post, I think I've got all the bolt on similar to yours (Sam's total package). We are still refining the tune. My next step will be to upgrade the injectors but will wait for next year to do that. I have access to E85 - so will be watching to see how far you can take yours safely...

 

When you do injectors I would go bigger than 1kcc. Can you get it done with the 1kcc yes but at a high duty cycle. I prefer to have buffer in my setup... Maybe the newer 1050 or 1300 is what I would use for VTG upgrades that run E70-E85 for fuel.

A change in air density from one day to the next can move your duty cycle 5%, I see it in my data.

 

Good feedback - I'll keep that in mind when I go for it...

 

Again,


very nice work! Can't wait to see the final numbers on your beast!


She must feel like a beast on the street!

 

Don't tell Sam but it runs pretty good for a daily driver . I gotta keep pushing him for higher power. If he knows I'm happy he will cut me off from pushing the tune.

Hopefully we will have more data as the tune revs keep coming. Its still conservative and smooth power delivery.

 

LOL, I can attest to this theory. I've been bugging Sam almost daily to keep bumping it up as long as the logs look good. I think after today's update we've about
maxed out the stock injectors. I've got up to 507 air flowing through and it's just humming along with hardly no knock. I just need more octane now.