533i v3: Turbo LS

Post your photos and videos here!
mitch5
Posts: 432
Joined: Feb 12, 2014 1:36 AM
Location: phoenix

533i v3: Turbo LS

Post by mitch5 »

After 2 years of modifying my car I am approaching upon version 3. v1 involved a turbo m30 and v2 involved a marginally better turbo m30, what i did take pictures of is here. After crunching the numbers, i decided i wanted to make some real power(500+ hp) all without spending more than what i had in the m30 setup. The m30 is a great motor but what steered me away is the high machining cost and lack of aftermarket valve train parts. Before going further into this i should give a bit of back ground, im 21 finishing up an ME degree and hate paying people to do work i am capable of. With that being said i plan to make some decent power while spending less than some might drop on an m30 rebuild(3 k). To accomplish this will take a bit of creativity.

Here's my recipe for success:
complete gen III 5.3 lm7
m22(rock crusher) 4 speed muncie
bbc bellhousing
ms3x
hx55 turbo
ls7 cam
7k rev limit

I wasn't about to spend 2k for a t56 and who needs 6 gears Anyway? Chevy kept the same sbc bellhousing pattern on the ls minus 1 bolt, on the ls the crank is .4 inch shorter than a sbc. This mean that with the proper spacer and bellhousing you can use just about any gm trans on the ls. i scored the muncie at a swap meet for $320 , came with the hurst competition shift linkage and aluminium bbc bellhousing too. It needs a mount welded on and could use a rebuild so i will be handling that soon.
Image
Image


First job was to get the motor in, due to the trans having side linkage the tunnel was cut. I set the engine as far back and low as i could. I was tempted to cut the firewall and get that sucker behind the front sub frame but after all this is a street car. The motor mounts are tigged dom tubing with a good amount of gusseting. I used the stock mount location but reinforced it and used some delrin stock i had as a damper. The trans mount was straight forward. All ls engines minus the ls2 gto use a rear mounted sump, this is not optimal for the e28. The ls2 pan would have ran $300 and would still need modification so i made my own pan. The pan uses a 1/4 in flange and 1/8 aluminum for the walls. The design is mean to be performance oriented and will have internal baffling. The filter will be also be remotely located.
Image
Image

Next was sheet metal work, i had to seal up the tunnel, since the interior was out ethics got the best of me and i decided to repair the rust. The worst of it was in the the torque box area. I also cut the front frame rails moved and few things around to make room for my craigslist sourced c&r radiator.
Image
Image
Image
Image
Image
The next hurdle was getting the accessories to work, yes i could spend $500 on f body accessories but that would be too easy. Sidenote, while the f-body cars use a shorter crank pulley, the waterpump is the same length so there is no practical gain aside from the lower vertical height. The main issue is the alternator sits way to high and hits the hood. The easiest solution i came up with was to move the alternator to the ac location and mount it low, while also running it off the 4 rib ac belt. Then all i had to do was cut/shave the stock powersteering bracket and fab up an new serpentine belt pulley. The stock 5.3 intake flows about ass swell as a ls6 intake so i will be using it, By cutting off all the bracketry and shaving it down i was able to get the hood closed. Due to my engine positioning i will have to mount the booster remotley.

The photos i uploaded are a few weeks old and dont show some of the progress made. but give a general idea of whats going on. Im a one man team so i expect it to be on the road in a few months.
Last edited by mitch5 on Feb 14, 2017 3:45 AM, edited 1 time in total.
T_C_D
Posts: 7733
Joined: May 27, 2009 11:42 AM
Location: Twin Cities
Contact:

Re: 533i v3:ls swap

Post by T_C_D »

Cool. Couple of notes. Truck manifold doesn't flow nearly as well as the LS6 manifold. You will need to spend actual $$$ to have a safe 7k valve train. Pushrods, rocker arms, valve springs, retainers, trunions.
mitch5
Posts: 432
Joined: Feb 12, 2014 1:36 AM
Location: phoenix

Re: 533i v3:ls swap

Post by mitch5 »

Im sure the actual flow numbers might vary but i went off this online test of them for a comparison, 8 hp difference on a 6.0 test motor. The intake is a lot nicer ascetically but i didnt think it was worth the money to upgrade. http://www.hotrod.com/articles/20-ls1-i ... ds-tested/

I'm in the process of collecting parts for the valve train. So far i plan to use ls6/ls2 behive springs, some hardened pushrod, comp trunnions, ls7 lifters and upgraded rockers if i find a good deal. Along with some arp studs on the rods.
mitch5
Posts: 432
Joined: Feb 12, 2014 1:36 AM
Location: phoenix

Re: 533i v3: Turbo LS

Post by mitch5 »

I have been picking away at the car, finalized the turbo. Got a holset hx52 off a volvo semi truck, quick specs is factory 67mm Comp / 72mm Turbine. it has a small turbine housing but if that becomes an issue i can use a larger hx55 hotside. The goal here for me is super quick spool and moderate boost. The headers are tubular 1.75 into a 2 in cross-over, then those go into the divided t4 flange. There is 3.5 vband that reduces to a 3 inch downpie, all mild steel. Ill take better pics of the headers when i get the motor out of the car again.

Got all the accesories figured out and modified the truck wp for my needs, the alternator is getting run off the 4 rib ac pully. Cut the stock truck bracket to retain the ps pump and added an pullet for the serpentine.

The brake booster is relocated but not finished till i can get some bushings made. Im in the process of getting a intercooler fitted then it should all start coming togther.

Image
Image
Image
Image
BimmerDan
Posts: 896
Joined: Feb 12, 2006 12:00 PM
Location: Kearney, Nebraska

Re: 533i v3: Turbo LS

Post by BimmerDan »

nice work. subscribed
T_C_D
Posts: 7733
Joined: May 27, 2009 11:42 AM
Location: Twin Cities
Contact:

Re: 533i v3: Turbo LS

Post by T_C_D »

Why didn't you leave room for an air filter?
sixxxer
Posts: 31
Joined: Feb 21, 2017 10:49 AM
Location: Nj/NY

Re: 533i v3: Turbo LS

Post by sixxxer »

T_C_D wrote:Why didn't you leave room for an air filter?

Most likely the filter is going through the opening for the headlight.

Image
mitch5
Posts: 432
Joined: Feb 12, 2014 1:36 AM
Location: phoenix

Re: 533i v3: Turbo LS

Post by mitch5 »

Nope therers room for a filter. i use a 4inch to 3 inch transition elbow then run that into the airbox that is welded in the between the frame rail and fender but behind the bumper.
tig
Beamter
Beamter
Posts: 9233
Joined: Mar 18, 2013 6:25 PM
Location: Durango
Contact:

Re: 533i v3: Turbo LS

Post by tig »

Hero status, right here.
mitch5
Posts: 432
Joined: Feb 12, 2014 1:36 AM
Location: phoenix

Re: 533i v3: Turbo LS

Post by mitch5 »

Making progress:

engine

self ported 706 heads
polished chambers
decked and cc at 61
9.5:1 comp
block drilled and tapped for ls2 dampner
ls2 chain
comp dual valve springs
ls7 cam 211/230 .560/.557, converted to front cam sensor. I got the cam for cheap
ls7 lifters
3/8th pushrods
stock rockers
trunnion kit
shimmed stock oil pump
ls1 2 layer steel gaskets
stock head bolts
modified truck water pump
Stock truck manifold(clears the hood)
hand filed alumnim plate to clock the water pump inlet
modified stock truck brackets, added pulley and moved alternator
decapped truck injectors(~75 lb/min)
gold paint

I spent the money on the parts that will let me rev this thing. The oilpan is a unit i came up with and modified the stock pick up tube for the front sump, im running a remote filter so i drilled and tapped the block for 1/2 npt fittings. I personally dont trust the way the stock oil pan gasket seals between the pan and block. I got a used 6 puck 10.5 sbc chevy clutch that should hold 700 hp. Flywheel is the single most expensive part of this setup. Due to the ls crank spacing a .400 thicker flywheel is needed to properly engage the trans shaft. Got a billet steel 168 tooth flywheel made by a place called lsc flywheel for $450. Had it specd so i can use just about any gm clutch pattern. I plan on using the stock slave and clutch arrangement. If anyone has a hookup on a driveshaft shop let me know.

hope to have this thing running or atleast cranking in 3 weeks
Image
Image
Image
Image

Image

Image

Image
Image
Image
Image
Image
Image
Image
Image
Image
Image
T_C_D
Posts: 7733
Joined: May 27, 2009 11:42 AM
Location: Twin Cities
Contact:

Re: 533i v3: Turbo LS

Post by T_C_D »

Good progress. What diff ratio you thinking?
tschultz
Posts: 4101
Joined: Mar 01, 2009 7:58 PM
Location: Denver, Colorado
Contact:

Re: 533i v3: Turbo LS

Post by tschultz »

Nice work!
mitch5
Posts: 432
Joined: Feb 12, 2014 1:36 AM
Location: phoenix

Re: 533i v3: Turbo LS

Post by mitch5 »

just running the 3.25 unit i got. the gearing on the m-22 is 2.2/1.56/1.28/1.00 , with my tire size 4000 rpm nets 85 mph, not an autobahn cruiser but a 2.93 would help
LSXBeemer
Posts: 144
Joined: Sep 20, 2014 1:44 PM
Location: Seattle

Re: 533i v3: Turbo LS

Post by LSXBeemer »

Nice progress.
mitch5
Posts: 432
Joined: Feb 12, 2014 1:36 AM
Location: phoenix

Re: 533i v3: Turbo LS

Post by mitch5 »

Finished up my engineering degree this last semester but still managed to get it completed(6 moths later). I had a setback where the oilpan exploded due to what i believe were fuel vapors accumulating in the oil pan. Back story was that i left two coils unplugged while i was working on the idle in my driveway, it was open dump so it was hard to even hear it, 10 minutes later boom and 8 qts of oil on my driveway. Fixed the original pan i made but now im chasing leaks since i attempted to yamahabond the pan with the motor still in the car.

I started tuning it yesterday and due to some misleading turbosmart wastegate spring marking i had 14 psi go into the engine while it was lean and now shes smoking. Thought i had it set to 7 psi but the damn thing spooled to fast and even though i thought my map was rich it wasnt rich enough. Might be doing head gaskets but theres no coolant in the oil or oil in coolant so ill keep tuning.

I have this thing tuned through third gear and its scary at 10psi, i have some 245 sport compounds but at wot it spins in third. The ls7 cam in this thing is sweet because at high rpm it just pulls. With the current state of the car i will probably be chasing little bugs for the next month. heres a break down of the current status

Good:
makes power
muncie shifts like butter
powersteering works great
keeps cool in 110 az heat

Bad:
leaks oil due to some faulty jic fittings
smokes due to blown holset turbo or possibly head
transmission whines really bad, proably due to mixed gears
no traction
hood wont stay closed

pictures
Image
Image
Image
Image
Image
Image
Image
Image
Image
Image
Image
Image
Image
Image
Image
Image
Image
Image
Image
Image
Image
Image
mitch5
Posts: 432
Joined: Feb 12, 2014 1:36 AM
Location: phoenix

Re: 533i v3: Turbo LS

Post by mitch5 »

It's been a longtime since i have updated this thread but be rest assured i still have this car....running but not driving. I'm so deep on this car that the only logical thing to do is keep throwing money at it. The goal of this build is now to make it the meanest e28 around, not the quickest or highest powered but with a turbo v8 hooked to a 4 speed thatll spin 7500 rpm....it''l be mean.

I would love to add photos but embedding with gmail seems to be a pain. I will get around to it. Here is a timeline of events

2017
blew up a piston in the iron block 5.3, blammed it on overboost inncident
slapped new piston in
did a drift event then engine started having excessive smoking
decided to throw 20lbs of boost in the engine since i had plans for a new one. I have never gone so fast in my life
siezed the 5.3
discovered my decapped injectors were causing one cylinder to run lean hence why i destroyed two pistons. I cheaped out the first time around but not this time.

The plan after that was to build a l33 5.3, which i did.
gen 4 l33 bottom end rebuilt
arp studs
new oilpump
my homebrew ported heads 706
inspected and reused the top end
new 80 lb deka injectors
holley hi ram intake
-8 fuel system
magnafuel reg


Thats all for now, ill update more once i figure out an efficient photo embedding method. Till now here are some video links of someone else driving the car on a closed course, id put the volume on

https://photos.google.com/share/AF1QipN ... tPdTVNekhn

https://photos.google.com/share/AF1QipN ... tPdTVNekhn

https://photos.google.com/share/AF1QipN ... tPdTVNekhn
e38740imd
Posts: 473
Joined: Jun 17, 2013 12:36 AM
Location: Maryland

Re: 533i v3: Turbo LS

Post by e38740imd »

Great build!

cant wait to see more.



your welding skills are awesome. if only you were local :(


im just getting around installing the m30 intake manifold i bought from you forever ago!
mitch5
Posts: 432
Joined: Feb 12, 2014 1:36 AM
Location: phoenix

Re: 533i v3: Turbo LS

Post by mitch5 »

e38740imd wrote:Great build!

cant wait to see more.



your welding skills are awesome. if only you were local :(


im just getting around installing the m30 intake manifold i bought from you forever ago!
lol, thats awesome your finally getting around to install. Funny how parts will sit around for years.
mitch5
Posts: 432
Joined: Feb 12, 2014 1:36 AM
Location: phoenix

Re: 533i v3: Turbo LS

Post by mitch5 »

Finally got around to working on the car. I took pictures but still haven't had the time to create a new process for photos since Photobucket went by the wayside.
-Installed the IE camber/toe posi lock adjustment
-Reinstalled my machined trailing arm and subframe delrin bushings
-Installed the new to me ground control coil overs in the rear

The rear of the car is now finished, next will be the front. Still decideding what i need to replace while in installing the new coilover assemblies.
mitch5
Posts: 432
Joined: Feb 12, 2014 1:36 AM
Location: phoenix

Re: 533i v3: Turbo LS

Post by mitch5 »

As of today this car is street legal, gotta love arizona.

Big updates, in the fast few months i have done the following.
-installed coilovers
-6 point cage with nascar door bars, 1.5 .120 DOM,
-5 point harness
-installed a stock seat for the passenger
-rewired the car and setup all new gauges, got a great deal on SPA gauges and now have digital readouts for rpm, oil temp, oil pressure, fuel pressure, pre and post radiator coolant temp and voltage.
-Ran all new teflon fuel lines, added a 2 stage filter

Now that this thing is street legal i can work on street tuning it and then eventually getting some dyno time. Here are some picture of the current state.
ImageIMG-2444 by mitchell markulis, on Flickr
ImageIMG-2447 by mitchell markulis, on Flickr
ImageIMG-2442 by mitchell markulis, on Flickr
ImageIMG-2441 by mitchell markulis, on Flickr
ImageIMG-2438 by mitchell markulis, on Flickr
ImageIMG-2440 by mitchell markulis, on Flickr
tschultz
Posts: 4101
Joined: Mar 01, 2009 7:58 PM
Location: Denver, Colorado
Contact:

Re: 533i v3: Turbo LS

Post by tschultz »

Is this just a street monster or do you plan to drag race or anything?
mitch5
Posts: 432
Joined: Feb 12, 2014 1:36 AM
Location: phoenix

Re: 533i v3: Turbo LS

Post by mitch5 »

What else do you do with a car like this besides drifting, eventually as the car gets more shaken down i plan to do track days. There are a few more safety features i need to get it up to snuff for nasa or even nhra. I would love to see what it will do in the 1/4 mile though.

The next thing im trying to figure out is wheel/tire combos, i would love to find some nascar style steel wheels in a 17 inch size, i think it would be a econimcally way to get a custom offset and width.
mitch5
Posts: 432
Joined: Feb 12, 2014 1:36 AM
Location: phoenix

Re: 533i v3: Turbo LS

Post by mitch5 »

I finally painted this piece of crap and plan to drive it. Single stage black was probably the wrong color for the level of body work needed but it was the right price. A while back i decided a barely legal high hp project car that i created in my teens was a waste of time for someone in their 20's so the car sat for years until last winter.

This was/is an effort to make the car more streetable, mainly so i can park it on the street and not get harassed by the city.

-With the help of Wkholer I was able to procure a rear bumper that would have been a direct fit, had i not removed the entire trunk.
- e34 front bumper, which is missing almost 70% of the front due to an intercooler.
- Filled in some of the giant hood hole
-less loud exhaust

here are pictures of that journey



Image
Image
https://lh3.googleusercontent.com/pw/AI ... WDp2=w2400
Image
Image
Image
Image
Image
Last edited by mitch5 on Aug 08, 2023 6:22 PM, edited 2 times in total.
mitch5
Posts: 432
Joined: Feb 12, 2014 1:36 AM
Location: phoenix

Re: 533i v3: Turbo LS

Post by mitch5 »

Bought a new Chinese holset center section(had a rock ruin the old compressor), flow testing all the clogged injectors(1 year old fuel) and started tuning. After driving a westy vanagon for 2 years, this thing feels like a rocket ship.
Post Reply