For Sale:  Stage 3 Maximum PSI Turbocharged E46 M3

The car was built for a friend/customer living in Uruguay and was completed in 2014.  He flew out to NJ in the summer of 2014 to enjoy taking the car to MPACT at Pocono Raceway, and then flew home.  It has been driven periodically through the last few years, and has been stored indoors down in southern Florida.  Technically it is still a new build that was never delivered.  It is an amazing car.  The plan was to purchase a donor vehicle in the US, turbocharge it, and have it imported to South America.  After 3 years of red tape, it is apparent that the car is not able to be shipped to Uruguay, and my customer has decided to sell the car.

2004, Black on black, ~85k miles

660whp 93 octane, 809whp MS109

 

 

 

 

 

 

 

 

 

 

Maximum Psi Stage 3 Turbo Kit – 6MT – Catless
3.5″ downpipe, full 3.5″ exhaust with quad tips and e-cutout
ATI balancer
UUC feramic twin disc clutch kit
Remove tint from rear lights, re-clearcoat
Remove subframe, reinforce chassis with plates, install, align vehicle
Poly subframe bushings
Poly rear trailing arm bushings
DSS axles
modified multi-plate E32 diff assembly
Racelogic traction control – E46 CAN firmware, black digital adjuster
Stop-tech Radi-cal big brake kit – black caliper, non-j hook rotors
BW/C&R Radiator
bimmerworld silicone rad hoses
HD Electric fan, install kit, relay harness
BW/C&R Oil cooler
Power steering pump
Radar-mirror modded mirror for V1 radar detector and DM100
PLX DM100-OBD
PLX SM-AFR
PLX boost
Michelin Pilot rears

Interior: 8/10
New Interior Pieces (cup holders, center console)
New OEM shifter was installed about a couple years ago
Custom painted interior trim pieces (Semi-Gloss black)
V1 radar detector
Weathertech floor mats
Interior Xenon Bulbs
Solaris Invisibulbs

Exterior: 8-9/10
Lightwerkz Quad Projectors (6000k outer/3000K inner)
VMR 19″ Ultra Staggered CSL reps (Only wheels)
OEM CSL Trunk
KWV2 Coilovers
Status Gruppe CSL Front Bumper (Shaved intake hole)
Michelin pilot sports Ps2 275/30R19
Tekarbon Diffuser
AC Schnitzer Strut Bar (Paint Flat Black)
Tinted Windows 35% Side 15% Back
Jet Black Side Gilles
Jet Black Hood Grills
Smoked Corner Lights
Black and Chrome Emblems For Trunk And Hood
Monochrome badges for gilles

The cost of the car, the parts, and the labor was well over $75000.  Buyer is motivated to sell, please make an offer.  Please contact sales@maximumpsi.com for more info.

Maximum PSI F8X M3 updates – keyed crank hub in testing!

We decided to purchase a F80 M3 for our latest shop car in late 2015. The S55 motor found in the new M3 and M4 is an awesome powerplant, and we fell in love with the new body style.  We quickly developed multiple bolt-on parts for this platform including front-mounted intakes, silicone charge pipes, and downpipes.  The car went from stock to full bolt-ons including turbo upgrades and fuel system changes in a short period of time.  We quickly jumped into the #1 drag racing spot with a 10.2@137mph in the 1/4 mile.  Everything was great.  We made some additional changes, and then our M3 suffered from a spun crank hub.  This happened with only ~3000 miles on the car.  We quickly discovered most of the exhaust valves were bent, and we pulled the motor and put the car on the back burner.   TPG tuning was another vendor that had experienced this failure early on, and while they tried to come up with a solution for their car and customers, there were some failures with some of their earlier hub solution attempts.  The BMW forums went on a witch hunt trying to accuse TPG of selling parts for a failure that didn’t exist, and a lot of drama popped up on multiple sites.  I understand the frustration of customers that purchased an upgraded part that still failed, but TPG was only trying to offer the community a solution to a problem that is very real.  To anyone unfamiliar with the S55 timing gear/crank hub design you can read up by clicking here.

We eventually got the car back together with upgraded rods and pistons, and we installed an aftermarket crank hub from another vendor.  It had a different bolt, and combined the hub and the first timing gear into a single part.  It still used the stock oil pump gear.  We hoped that it would fix the issue, however we knew there was a good chance it would spin again due to the lack of any sort of pin or keyway.   We rushed to get the motor and car assembled, and we took it to MPACT east in July 2016.  The car only made it about 5 passes before the hub spun again during a burnout before a 1/2 mile run.  This time we were lucky as there was no piston to valve contact.  We once again put the car to the side and dealt with our shop move to our current new facility in South Amboy, NJ.  At that point we decided to focus on making a new crank hub and gear design.  There were multiple design constraints, including assembly process, existing crankshaft snout design, and cost.  A new crankshaft with integrated gears would be my first choice, but it would be extremely expensive and would require a complete teardown of the engine and would be very annoying to assemble the chains since everything is one piece.  We opted for a design that had an interlocking crank hub, timing gear, and oil pump gear.  The three parts all lock together with beefy keyways, and the gears are new units made by us.  The tricky part was coming up with a design that was also keyed to the end of the crank, and we tackled that with a drill fixture and hardened pins.  The install requires dropping the oil pan and removing the timing components.  To anyone that is interested in our crank hub solution, please email us at sales@maximumpsi.com to be put on a contact list.

We got our F80 M3 back together the week before MPACT 2017 with our keyed hub along with some more upgrades.  The car worked flawlessly on pump gas at MPACT, and we put it back on E85 after the event.  Since then we have been to the drag strip for two test days, and have made 5 10 second passes, including our new record of 10.1@139mph.  We will continue to romp on the car and try and put the components to the test.  We want to get some more time on our car and two other cars before making a larger second batch of gears, but the first test days were positive!  We look forward to pushing the platform further instead of worrying if the next drag pass is going to result in pulling the motor apart to rebuild or retime.

– Mike and the Maximum PSI team

 

 

 

 

 

 

 

Maximum PSI and Bimmer Clinic have joined forces!

Bimmer Clinic and Maximum PSI!  New location starting Feb/March 2017!

Looking for a reliable and qualified shop to service your BMW? Looking for a team of specialists to recommend and install performance parts and software? Look no further – Maximum PSI and Bimmer Clinic have teamed up to provide a one-stop shop for all of your BMW needs.  We have you covered for dealer-alternative BMW service and repair, performance upgrades, software/dyno tuning, and track prep/support.  Our new 11000 square foot facility is conveniently located in South Amboy, NJ near the Parkway, Turnpike, 440, 287, 9/35, and the South Amboy train station.  The new facility has a large customer waiting area that you can relax and enjoy a cup of coffee or pull out a laptop and get some work done while you wait.  We stock all the necessary BMW fluids, and have an extensive list of service tools to get the job done quickly and correctly, the first time.  We have multiple software solutions depending on your vehicle to maximize power, reliability, and fuel economy.

We are currently operating out of Bimmer Clinic at 1400 Rahway Ave, Avenel, NJ 07001 until our new building is ready in February/March(assuming no delays!).  Our new shop address is 7061 Rt 35 S, South Amboy, NJ 08879.  Please give us a call at 732-218-7632 or email sales@bimmerclinic.com to get a quote or set up an appointment.

Here is a list of some of our equipment:

Autologic, Rheingold/ISTA-D, INPA, GT1, Snap-on VARIS diagnostic tools
Extensive collection of OEM and aftermarket timing and service tools
Hunter hawkeye elite wheel alignment system
Hunter Tire machine
Hunter Road force tire balancer
7 Nussbaum lifts
Gruse MHT 1200 Hydraulic lift table (for complete engine/trans/subframe removal)
Miller Dynasty 300DX TIG welder
Snap-on, Lincoln, and HTP MIG welders
Dynojet Chassis dyno
Bentec Mandrel bender
JD2 Model 4 electric/Hydraulic bender
Huth bender/swager/expander
DoAll 13″ Vertical band saw
DoAll Horizontal band saw
Wilton Belt sander

  
   
   

 

New Product Development

We have been busy rolling out several new products for the F8X platform including our intakes.  I wanted to post up some pictures of the CNC, Laser, and metal fab equipment that we use to make our products, along with some “behind the scenes” pics of what is to come.  They say a picture is worth 1000 words, so here is a short story or 2!


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Maximum PSI F8X Front Mount Intakes dyno test

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We did some back to back testing with stock airboxes and then with our front mount intakes to see the actual gains on our shop M3.  Same day, same conditions, same car.

Test conditions:
Hood closed.  3 runs each, tested with engine and components at operating temperature with brief cooldown between runs.  DCT trans, 5th gear. Runs 0-2 are stock airboxes/filters/ducting.  Runs 4-6 are Maximum PSI intakes without socks

Test Vehicle:
2016 F80 M3
JB4 on Map 2 – 93 octane fuel
Maximum PSI catless downpipes
Stock exhaust

We were expecting 10-15whp at best at this power level, and possibly larger gains on E85, meth, etc.   Upon reviewing the results we immediately noticed a trend.   If you compare runs 0-2 vs 4-6 you can see significant gains above 5700rpm even with a JB4 and downpipes.  The gains will likely be better with higher power output cars(upgraded turbos, full exhaust, race fuel/e85, etc.).  We normally post all of our results with SAE correction, however the N54/N55/S55 community seems to use STD or uncorrected, smoothing 5.

STD corrected:

intaketest1

Uncorrected:

intaketest3

Here is a graph of the best run from the stock airboxes(blue) vs the best run from the Maximum PSI intakes(red).  You can see a notable gain in the upper rpm of over 30whp:

STD:

intaketest2

Uncorrected:

intaketest4

Results:

Why did our intakes make more power than stock (and other aftermarket ones)?  This is where I get to speculate a bit:

  • The oem system (and several aftermarket systems) use the factory ducting that basically draws air from the same place.  The oem system is completely sealed, and has a charcoal filter plus a paper one(restriction#1).  It then draws ALL of the air through the kidney ducts (restriction #2).
  • Aftermarket intakes that use the lower halves of the oem airbox and oem ducting have larger filter elements, however they are now drawing a blend of hot air from the engine bay and the air coming through the ducts.  That results in an unrestricted pipe, however AIT’s are higher, resulting in hotter charge air temps.  The intercooler is only as efficient as the air entering the system.
  • If you decide to try a drop-in filter like BMC or K&N you may eliminate some of the restriction, however it is still using a torturous path with rectangular passages and various less-than-smooth transitions.  Our system is 3″mandrel bent piping throughout.

 

We wanted to address a few customers questions and concerns:

Cooling:
We plan on making significant power with this platform, and took that into account when designing the intakes. We chose the filter size and location for performance and aesthetics. The filters are large, however BMW did an excellent job of ducting all airflow through the kidneys and into the heat exchanger and radiator, regardless of what is in front of the ducts. If it is needed, a slightly smaller filter length can be used. Until that point, this is the route that we prefer. There is plenty of airflow to go above and below the filters and into the ther cooling components. The filters simply get first prority.

Rain:
We have obviously took into account driving these cars in the rain with exposed filter elements. I have done extended driving through heavy rainfall with no issues. The ratio of airflow going through the filters vs the amount of rain that will contact and be ingested through the filters is not enough to have any concern. People pay good money for water injection to allow for charge air cooling. Look at the M4 GTS that comes with water injection from the factory! I’m not saying we are intentionally trying to have water enter the system, only to say the small amount contacting the filter elements will dissipate long before there is any concern for water ingestion. Someone equated driving in the rain similar to spraying a power washer at the air filters. That is certainly NOT the case. A power washer directed at the filters.

Hot air:
Regarding hot air being drawn from the radiator to the filter, the only situation that would exist is sitting at idle, where it does not matter.  As soon as there is forward motion the car gets forced air into the kidneys. The airflow will be past the filters, and through the radiator.  There will not be enough time to have any heat radiating forward towards the filters.  We easily confirmed this on the dyno with relatively poor airflow.

Click here for more info and to purchase in our online store!

Maximum PSI stage 2 E46 runs a 9.74@145.99 in the 1/4 mile!

We took the shop E46 M3 to MIR for a track rental and we were able to make multiple passes and chip away at a 9 second pass.  The end result was a 9.7@145.99mph, making it the fastest E46 in the US and the first in the 9’s.  We plan on continuing to push the car with the stock motor for now, and eventually we will install the built motor and larger turbo with our sights on an 8 second run.

MPACT Motorsports Festival 2015

 

Maximum PSI was an event sponsor for the second year in a row at MPACT Motorsports Festival at Pocono International Raceway.

We brought out our Stage 2 Turbocharged E46 M3 shop car along with several customer turbo cars.  We had a great time checking out the cars, hanging out with like-minded enthusiasts, and most importantly, thrashing on the cars!  We participated in the roll races, put on a respectable performance in the burnout competition, and enjoyed a lap in the Sarli Motorsports Drift Taxi.  We look forward to MPACT 2016!

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Videos – Make sure to click HD in the settings!

Roll racing:

Sarli Drift Taxi:

 

 

User reviews are always nice!

One of our Stage 1 E46 M3 turbo kit customers posted up a review on one of the BMW forums.  The original review can be seen here: http://www.m3forum.net/m3forum/showthread.php?t=504621

What I bought:

MaxPsi E46 M3 Turbo Kit (91 and 100oct)
MaxPsi 3″ Exhaust system (used)

Customer Service:
As everyone already knows Mikes reputation is top notch. I was bugging him at his most busy times and he still found the time to sit down and deal with my questions. You can really see the pride he has in this kit and will do whatever it takes to solve any issues.

Shipping and Quality:
First off, the freight shipping got from NJ or AZ in 3-4 days! Everything was packed perfectly and everything was there. Being that i am an aerospace welder/machinist for a living the first thing i look for in any part is the quality. All of the welding on this kit is awesome and is up to my high standards. I was very impressed with the intake manifold, the 6 runners are all CNC machined to perfection.

Install and Fitmet:
I have done 7+ E46 M3 Turbo installs so the install was fairly easy for me to tackle. Even if this is your first install Mike provides everything you could possibly need to handle it, the instructions are very detailed. Anytime you design something on another car and fixture it you can expect a little variance on fitmet, NOPE, this kit fit PERFECT.

Driving:
I had expected on first start up to have to solve some issues, but everything fired right up and idles perfectly. On the first drive i was over boosting a little bit, but after a few adjustments it now holds right at 9psi every single time. Since then i have been beating on the car and everything is flawless. This is my daily and i drive it 50 miles a day.

All in all i am extremely pleased!! Everyone should own one of these kits, Mike dialed these in to perfection!!

Winter update – 2.22.15

THE GOOD:

We have been busy cranking out turbo BMW’s. We have over 35 E46 M3 kits out there, and we are currently assembling and finalizing two Stage 4 cars at the shop, along with our first S54 Z3 kit. A stage 3 car is down at Technique Tuning in Florida for calibration development with larger ID1000 injectors. We ran an 8 second 1/4 mile with my E36 M3 at the end of last year, and I sold the car to a customer that will continue to push it further. This will allow us to focus on pushing the E46 development further rather than getting distracted between the two cars. It was a long, rewarding road with the e36. First in the 9’s, first in the 8’s! Sad to see her go, but it was a necessary progression.

8 second compilation video, 1/2 mile roll race and other media:https://maximumpsi.com/videos/

If you follow us on Facebook or Instagram, some of you have already seen the transformation of my E46 M3. Last year we installed a bimmerdiffs upgraded differential, along with all new poly bushings all around. We also performed the subframe reinforcement before buttoning it up. The car currently has the entire interior removed to begin the NHRA roll cage fabrication (complete with parachute and window net). The car is also getting a driveshaft loop and battery cutoff per the rulebook. While the cage is doing in, I am also installing a carbon trunk, carbon diffuser, and carbon roof. We also fabricated a larger 3.5″ single exhaust (that can be used with any of our different kit levels, and it has options for a single exit using a carbon diffuser, or quad exit using an oem style diffuser).

We suffered numerous 6 speed transmission failures with the e36 running an e46 M3 getrag box. They don’t stand a chance when the car makes almost 900 ft/lbs of torque!

I have a 6 speed dog box getting built by Samsonas Motorsport for my car. It uses an OEM ZF E36 transmission case with all new gears and internals, along with a CNC’d spacer to make the case the correct length for the additional gears.I also have a new twin disc clutch from Comp Clutch to try out in the car. We will have feedback shortly. I have had it for a while, however I am waiting for the new transmission to arrive so I can install it at the same time. I also have a Tilton carbon triple disc clutch for when things get serious and the built motor goes in later on this year.

We are going to keep the stock motor in the car and race it as-is with our current Stage 2 hardware, however it will be using our flex fuel system(Yes, we are still working on it!) running E85. My car has over 30k miles with our kit, and I have no issue driving it anywhere. We drove the car ~1400 miles to PRI and back this year and I have been to florida a few times with it. We also thrashed on it when we went to Bimmerfest, Willow springs track day, and MFEST. Still running strong!

At the same time, we are also assembling a built motor for my car, so that once the flex fuel development is completed, we can swap in the built motor and Stage 4 components. Exciting times for sure!!!

THE NOT-SO-GOOD:

There have been some bumps in the road with our kits, but nothing that hasn’t been remedied. We had a few of our first intake plenums split at one of the welded seams. The first four cars were the only ones to have that issue, and they have all been repaired by now.

The major issue that we are still dealing with is cracking of the earlier tubular headers. We have always tried to do as much of the fabrication for our kits in-house, however the tubular headers take so much time to fabricate that we have other people fabricate them for us. There have been multiple failures with the first batch of tubular headers. The failures are caused by incomplete weld penetration. Over time some of the cars have had multiple cracks develop at various locations. We tried repairing the first few manifolds, however the time needed to strip the coating, blast the inside and outside clean, grind the cracked sections, and re-weld the entire header is too labor intensive. I will say that any of the later kits with non-ceramic coated headers do not need to worry about the issue since they were welded by another shop. Unfortunately we do not have the resources to replace all of the headers, so we came up with another plan.

We have used cast headers from SPA turbo on numerous E36’s over the years. With multiple tubular header failures, I decided to work with SPA turbo to duplicate our tubular headers into an identical cast manifold. After shipping them our tubular manifold, we soon had a sample that I ended up installing on my own car. The flow path and flange location is identical, however we were able to make more clearance for the rear cam sensor and A/C line. We also increased the inside diameter of the runners to account for some flow disturbances caused by the bolt hole recesses. I have the second revision on my car now, and I can say that the manifold performs as good or better than the previous tubular manifolds. We should be receiving our first batch of manifolds any day now, and the current round of kits are now shipping with them.

To anyone with a previous tubular manifold that has developed a crack: We will be selling the cast headers at a discount to help offset replacement cost. We apologize for the inconvenience, however it is not possible for us to cover the replacement expenses. If you have had the kit less than one year then the replacement header will be covered under warranty. Please email me at sales@maximumpsi.com and we can go over the details.

THE GOOD(again):

We raised the Stage 1 kit price! How is that good? We actually lowered the kit price to account for the cost difference of the cast header. We are now including an eBoost 2 EBC and AEM wideband, and gauge pod($850 in components) since we use them in every kit besides the first few cars that we did.

That’s all for now. 2015 should be a good year for turbo E46’s!

-Mike and the Maximum PSI crew