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Default Build Log: Matt's FFTEC 335xi E90 - 11-17-2015, 10:33 AM

Gentlemen,

This winter I am helping my good friend Matt get his E90 back on track. Up to this point there has been a lot of work done by various shops (which will remain name-less), some installs/projects were done right others were not. The attention to detail, or lack thereof on this car, really drives home the importance of having a skilled and trusted mechanic or in my case, doing it yourself! It is a little frustrating to spend time resolving issues that should never exist as they are easily avoided but at the same time I enjoy fixing problems and optimizing systems.

Matt and I have collaborated and made a plan for his car, to make it fast(er)! It is off to a great start with some choice upgrades but now it needs to be massaged into a complete and cohesive build. This is Matt's daily during the summers so it needs to be reliable and functional while eye-peeling fast. Personally I love aesthetics but not at the expense of function, it is often hard to achieve both or even strike a compromise but I enjoy the challenge and the when well executed the end results are awesome. Matt and I see eye-to-eye on this so this should be a fun project.

His car started life with a fairly unique configuration. It is an 2008-build LCI car but still has the N54 (sweet), in addition it is AWD and has 3 pedals! It has gone through a few iterations but here is the mod-list prior to me getting my hands on it.

FFTEC VFF900 (64mm Precision Bottom Mount)
Custom "Filthy Habits Fabrication" Single 3" Valvetronic Exhaust
ER Intercooler
ER Chargepipe (HKS BOV)
ER Competition Oil Coolers
JB4 G5

StopTech Trophy BBK
KW Coilovers
Rotiform Wheels
Toyo R888


As you can see, some nice parts but the fuel system needs to be addressed along with some preventative items, and some handling/drivetrain upgrades. But first the car needs to be running 100% before throwing more power, stress, and heat at it.

Let's begin,
Evan


The best "before" photo that I have


Replaced the unsightly brake-booster line with some heater hose and routed it under the charge pipe, much cleaner


Installed some AFE scoops, these in conjunction with the BMS cowl filters should help cool the engine as the air passing over the engine will extract heat.


BMS cowl filters installed


Oem steering wheel


Found a deal on an M3 wheel (Nappa leather), it was dirty but cleaned up nicely.


During


All cleaned


Detail

Comparison


Did some interior spot cleaning


Armrest


Datalogging via JB4 Mobile


Headlight washer hose popped off and fluid escaped


Ah, hell naw, what's up DOG!


Fog lights and trim deleted, they impeded flow to the oil coolers.


With the fogs and grills in place it was blocking most of the direct airflow to the coolers.


Much better, next will be some shrouds to help guide the air.


The center grill also blocks flow to the intercooler (which sits low) so it was removed as well.


A weeping cooler fitting, it was tightened, cleaned , and I will keep an eye on it.


Headlight washers are in the way, so they got deleted.


Washer hoses were capped and the system can be reinstalled if one chooses to do so


Fog connectors just hanging out


So they were zip-tied out of the way


Fender-liner openings were poorly cut for the oil coolers, driver-side


Passenger side


I used a razor instead of a dremel for a cleaner cut


Weeping KW


My OCD kicked in and I cleaned and straightened all intercooler fins


JB4 usb ran through the firewall


...and into the glove box


With the cowl delete the DME box sticks out like a sore thumb, so I cleaned, prepped, and Plasti-Dipped it black.


TB cleaned up


One of the previous shops said they cleaned the valves, which means that this build up if from <5,000 miles of use. You be the judge...

1


2


3


4


5


6


N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes, M5 Rear Suspension
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Trans Swap, MFactory SMFW, Spec Stg 3+ Clutch, UUC SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Lines +Ethanol Sensor
- JB4, Hexon RR550s, Custom Inlets, AR ***, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB Ext. PCV, BMS OCC
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illrider illrider is offline
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Default 11-17-2015, 11:53 AM

Looking good! What mount was used for the tablet?
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Default 11-17-2015, 12:03 PM

Quote:
Originally Posted by illrider
Looking good! What mount was used for the tablet?
That is my personal setup from my E61, it is a Mountek. I highly recommend the mount, it fits even better in the E90 than in mine!

The only issue I had was the magnet adhesive didn't cooperate with the hybrid rubber/plastic finish of my tablet and it started to slide, after a while of being annoyed I cleaned both surfaces and super glued everything. Something like 3M Very High Bond (VHB), the good stuff, would also do the trick.

Tablet is an Astro Queo, works fine, screen sucks and it is a little slow but has been reliable. There are likely better tablets out there but it's a decent deal considering it costs $45.

Evan


N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes, M5 Rear Suspension
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Trans Swap, MFactory SMFW, Spec Stg 3+ Clutch, UUC SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Lines +Ethanol Sensor
- JB4, Hexon RR550s, Custom Inlets, AR ***, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB Ext. PCV, BMS OCC
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illrider illrider is offline
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Default 11-17-2015, 12:10 PM

Quote:
Originally Posted by ucsbwsr
That is my personal setup from my E61, it is a Mountek. I highly recommend the mount, it fits even better in the E90 than in mine!

The only issue I had was the magnet adhesive didn't cooperate with the hybrid rubber/plastic finish of my tablet and it started to slide, after a while of being annoyed I cleaned both surfaces and super glued everything. Something like 3M Very High Bond (VHB), the good stuff, would also do the trick.

Tablet is an Astro Queo, works fine, screen sucks and it is a little slow but has been reliable. There are likely better tablets out there but it's a decent deal considering it costs $45.

Evan
I've never tried a cd mount before. Are you able to keep the navigation dvd inserted, while using the mount? Or is there not enough room for both?
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Default 11-17-2015, 12:11 PM

Quote:
Originally Posted by illrider
I've never tried a cd mount before. Are you able to keep the navigation dvd inserted, while using the mount? Or is there not enough room for both?
Both fit just fine.


N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes, M5 Rear Suspension
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Trans Swap, MFactory SMFW, Spec Stg 3+ Clutch, UUC SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Lines +Ethanol Sensor
- JB4, Hexon RR550s, Custom Inlets, AR ***, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB Ext. PCV, BMS OCC
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Spxxx Spxxx is offline
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Default 11-17-2015, 03:22 PM

The whole corner of that driver side oil cooler looks a bit bent.


M-Sport 135i - N54 - FBO - E60 - Mfactory LSD - MHD - JB4 - SPX Tuned
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Default 11-17-2015, 03:22 PM

Your attention to detail is great


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baja2700 baja2700 is offline
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Default 11-17-2015, 03:55 PM

Awesome work!
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Default 11-17-2015, 07:38 PM

Curious why you went with such a small exhaust? Were you wanting to keep the sound levels down?


2008 E90 6MT sports package, VM 6466g2, BMS PI, Fuel-It Stage 3+, JB4+MHD
2009 E89 Z4 DCT, JB4, MHD flash, DCI
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Default 11-18-2015, 08:36 AM

Quote:
Originally Posted by Spxxx
The whole corner of that driver side oil cooler looks a bit bent.
Good eye, it does look like the fitting took a hit at some point and that would help explain the leak coming from that fitting.
Quote:
Originally Posted by baja2700
Awesome work!
Thank you.
Quote:
Originally Posted by Sered
Curious why you went with such a small exhaust? Were you wanting to keep the sound levels down?
Keep in mind this is not my personal car, just a car I am working on. That being said I also have a single 3" system on my E61. Personally I am not going for WR HP levels so a clean/well built single 3" system should flow well enough for my needs. I do know it can be tricky to fit 3.5" and 4" piping under the 3 series. Keeping the car "quiet" was not the intention with these single pipe setups.

Interestingly, this exhaust was built while Matt had RB twin turbos which explains the merge collector, after the exhaust was on the car the FFTEC kit was installed with the 1-2 ********, so the exhaust splits for about 2.5' and rejoins for no reason. But the welds look great!

Evan


N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes, M5 Rear Suspension
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Trans Swap, MFactory SMFW, Spec Stg 3+ Clutch, UUC SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Lines +Ethanol Sensor
- JB4, Hexon RR550s, Custom Inlets, AR ***, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB Ext. PCV, BMS OCC
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Default 11-18-2015, 08:39 AM

So much better with a black DME cover.



Pump and Thermostat came in.


Interesting choice it vac line routing.


Exhaust was filthy from the coolant leak.


Filthy FILTHY HABITS


Cleaning


N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes, M5 Rear Suspension
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Trans Swap, MFactory SMFW, Spec Stg 3+ Clutch, UUC SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Lines +Ethanol Sensor
- JB4, Hexon RR550s, Custom Inlets, AR ***, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB Ext. PCV, BMS OCC
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Default 11-18-2015, 08:39 AM

Well just keep in mind, a single 3" flows less than stock piping when *******.


2008 E90 6MT sports package, VM 6466g2, BMS PI, Fuel-It Stage 3+, JB4+MHD
2009 E89 Z4 DCT, JB4, MHD flash, DCI
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Default 11-18-2015, 08:40 AM

That black dme cover looks great btw. I'm totally ripping this off lol


2008 E90 6MT sports package, VM 6466g2, BMS PI, Fuel-It Stage 3+, JB4+MHD
2009 E89 Z4 DCT, JB4, MHD flash, DCI
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Default 11-19-2015, 09:06 AM

Dropped the subframe to take a close look at everything and make accessing the waterpump/thermostat easier.


Interesting.... I removed the entire air charge system to examine all couplers and connections, good thing I did.


The PCV connection had come unseated from the filter and was spewing burnt oily goodness all over the outside of the filter, water pump, and everything else in the vicinity.


I figured the amount of oil saturated into the filter would make for an uphill battle cleaning it so I have a BMS ST Filter on order.


The heater hose laying directly on top of the engine was rather unsightly, especially since it was a VTA setup as it wasn't connected properly so I used a Vibrant crankcase filter I had laying around and situated a better VTA setup. The filter is down by the drivers feet with no sensitive items around and airflow to help evacuate the excess.


I thought this was the area where the cooling system sprung a leak. Things are tight in this area and it looked like the oem worm drive clamp may have cut into the cooling elbow supplied by FFTEC. Under further investigation, I found no damage to any cooling hose so maybe it was a poor connection, we will see!


Oh, Hi There!


This thing is so massive compared to my twins...


PT 6466 Gen II


It is a shame this thing isn't more visible...


Checking the WG springs


Black


Green


Based off the Tial MV-R Spring Chart this combo yields a .6bar/8.7psi

Removed the exhaust and gave it a wipedown.


FFTEC ** and Filthy Habits Fabrication mid section


FFTEC detail


Merge Collector


Gotta love v-bands


Welds


The ***-back was fabricated while Matt still had RB turbos, if only everyone knew this car would end up with a single turbo the exhaust could have been much simpler for the fabricators to build! lol


Rear section, dual Vibrant UQRs.


QTP Valve at the tip, when open exhaust passes through one resonator and out a 3" tip.


When the valve is shut gasses pass through a additional 2.5" diameter piping and another resonator to a 3" tip.


Tip detail


Filthy Habits!


N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes, M5 Rear Suspension
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Trans Swap, MFactory SMFW, Spec Stg 3+ Clutch, UUC SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Lines +Ethanol Sensor
- JB4, Hexon RR550s, Custom Inlets, AR ***, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB Ext. PCV, BMS OCC
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Default 11-25-2015, 09:20 PM

Before leaving to spend Thanksgiving with family I made some more progress on Matt's car. There will be some parts ordered and waiting for install upon my return ...early Christmas.

H222O pump is installed but I am waiting on the turbo filter to arrive to I can install that before mounting the thermostat. Once the cooling system is complete it will be time to reinstall everything and give it a whirl to confirm the everything is 100% and boost is being held properly.

Walnut Blasting is next on the list.

Evan


I ordered a BMS ST filter but unfortunately it is a little too large for the bottom mount, a Vibrant 10931 has been ordered as a replacement.


My previous spring assessment was incorrect, the table and spring chart Tial offers for 2012+ MV-R WGs are not the most intuitive an their spring paint isn't as pronounced as it looks online. At any rate, his WG was loaded up with 7.25psi of preload which will need to be increased a bit, and then a bit more as the mods progress. Probably looking for 12-13psi of spring initially before PI and E85. More importantly I discovered that the unused air port on his WG was unplugged, not sure when/how/why but it was. Some plugs have been ordered.


N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes, M5 Rear Suspension
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Trans Swap, MFactory SMFW, Spec Stg 3+ Clutch, UUC SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Lines +Ethanol Sensor
- JB4, Hexon RR550s, Custom Inlets, AR ***, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB Ext. PCV, BMS OCC
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Default 12-03-2015, 06:29 PM

Let there be airflow!



N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes, M5 Rear Suspension
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Trans Swap, MFactory SMFW, Spec Stg 3+ Clutch, UUC SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Lines +Ethanol Sensor
- JB4, Hexon RR550s, Custom Inlets, AR ***, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB Ext. PCV, BMS OCC
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ms335i ms335i is offline
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Default 12-05-2015, 04:23 PM

Your work is so impressive. I just want to leave my car at your place lol.
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Default 12-05-2015, 05:30 PM

Quote:
Originally Posted by ms335i
Your work is so impressive. I just want to leave my car at your place lol.
Thanks, I appreciate that.


N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes, M5 Rear Suspension
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Trans Swap, MFactory SMFW, Spec Stg 3+ Clutch, UUC SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Lines +Ethanol Sensor
- JB4, Hexon RR550s, Custom Inlets, AR ***, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB Ext. PCV, BMS OCC
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Lifestyler Lifestyler is offline
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Default 12-06-2015, 06:39 AM

detailed work ! great !!!


135i n54 FBO!
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Default 12-07-2015, 11:11 AM

I am 0-2 on ordering filters for the bottom mount, I struck out with the BMS shorty filter then the Vibrant filter didn't fit as the filter didn't taper enough, literally millimeters away from fitting, I finally went with the exact K&N the car ran originally. I should have taken better measurements these filter shenanigans are putting the build on hold as the filter must be installed before the thermostat goes in ...and everything else.


The MV-R springs and plugs arrived. Preload duty will be done by a black and blue spring, .8bar total for 11.6psi which should be good for 23-30psi-ish. Springs and missing airport plug were installed, MV-R is ready to go. I love the quality of Tial products, this MV-R was on my desk for the last week and I miss looking at it. I run a Tial BOV on my E61 and love it.



Some more goodies arrived: JB4 Anti-Lag, RB PCV, NGKs, 3.5bar sensor, new ** hardware


#Details



N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes, M5 Rear Suspension
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Trans Swap, MFactory SMFW, Spec Stg 3+ Clutch, UUC SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Lines +Ethanol Sensor
- JB4, Hexon RR550s, Custom Inlets, AR ***, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB Ext. PCV, BMS OCC
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BeGooD69 BeGooD69 is offline
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Default 12-08-2015, 10:38 AM

woow... nice ... i think I will remove my fogs and swap them for bars... make that air plow in too
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Default 12-09-2015, 10:27 AM

Quote:
Originally Posted by BeGooD69
woow... nice ... i think I will remove my fogs and swap them for bars... make that air plow in too
Bars?


N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes, M5 Rear Suspension
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Trans Swap, MFactory SMFW, Spec Stg 3+ Clutch, UUC SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Lines +Ethanol Sensor
- JB4, Hexon RR550s, Custom Inlets, AR ***, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB Ext. PCV, BMS OCC
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Default 12-09-2015, 10:46 AM

Still waiting for the filter to come in so I started to give the interior some attention. The car has ~75,000 miles on it and the interior is in great condition, a good cleaning helps breathe new life into it.

Evan

Garage Queens, Matt's E90 and Annie the Aussie.


After vacuuming, before leather cleaning.


Driver seat before


During, notice the difference in sheen from the oil and nastiness.


Before


After


N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes, M5 Rear Suspension
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Trans Swap, MFactory SMFW, Spec Stg 3+ Clutch, UUC SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Lines +Ethanol Sensor
- JB4, Hexon RR550s, Custom Inlets, AR ***, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB Ext. PCV, BMS OCC
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ThaCuda ThaCuda is offline
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Default 12-09-2015, 12:26 PM

Pleeeease tell me how to restore leather like you have done here. I have tried (with little effort to be honest) a leather cleaner with results nothing like this.


2007 335i 4dr JB4, Hexon RR600, Inlets, 4Bar, Index 12, Boost Concept Pump, DCI, FMIC, ** and full exhaust, Burger Meth, MHD BEF. Auto.
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Default 12-10-2015, 07:59 AM

Quote:
Originally Posted by ThaCuda
Pleeeease tell me how to restore leather like you have done here. I have tried (with little effort to be honest) a leather cleaner with results nothing like this.
I am using Chemical Bros leather cleaner along with a horsehair brush and a microfiber towel. Work is small sections (like 1 square of the seat) moisten the brush and leather with cleaner and agitate the dirt out of the leather, wipe away with microfiber towel. Repeat until "clean enough." I can make a little DIY when I get to the rest of the interior but for the best results you need to be thorough and methodical, that driver seat took me about 30 minutes to complete.

Evan


N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes, M5 Rear Suspension
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Trans Swap, MFactory SMFW, Spec Stg 3+ Clutch, UUC SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Lines +Ethanol Sensor
- JB4, Hexon RR550s, Custom Inlets, AR ***, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB Ext. PCV, BMS OCC
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