Aftermarket Turbo inlet pipe solution for the F85/F86 S63TU platform

[Cbozz]

Originally Posted by mvrt

Depending on how well the development goes for the inlet I can absolutely start working on an intake solution as well. Should be stopping by the shop in the next week or two to start measuring everything out

should make a full titanium intake all the way to turbo

[mvrt]

Originally Posted by Cbozz

should make a full titanium intake all the way to turbo

I like where your head is at

[Sophisticated Redneck]

Originally Posted by mvrt

Hey folks,

i noticed last night that one of the more common failures in the engine bay managed to make its way into my car, so rather than go and spend $150 on the same crappy plastic part that has been a point of failure for so many boosted BMW’s since the n54 days, I have decided to create an aftermarket upgrade for our platform.

I’ve reached out to my shop that has done custom work on my Supra as well as the x5 and we are currently in the process of designing a silicone inlet pipe solution.

That being said:

1.) if there are any of you interested in the final product, sound off below and subscribe to the thread.
2.) I will be posting photos and updates on the development once we get the car in there for measurements and test fitting.
3.) if there’s enough interest within the community, we will release it to the public.

Wish us luck!

Picture of the OEM turbo inlets (intake boot) for reference:

Titanium inlets would be awesome but trying manufacture the complex design needed for inlets at a decent price point would be an incredible challenge. I would instead look into making them out of a thermoplastic such as nylon6 with a 30% carbon fiber fill. It can handle the 250+ degree heat the inlets will see during shut down heatsoak. It is pricey stuff and not the easiest to work with but can be done. That is what I used for my E70 design I am coming out with that I have worked on and off for the past year. The Original N63 had particularly horrible inlets, very restrictive and fragile. Worked out really well, this 11 year old 186k mile engine is now producing X5M competition level hp (stock was 408). You could make some beefy inlets like I did that will never crack and last the lifetime of the engine.

[Cbozz]

Originally Posted by Sophisticated Redneck

Titanium inlets would be awesome but trying manufacture the complex design needed for inlets at a decent price point would be an incredible challenge. I would instead look into making them out of a thermoplastic such as nylon6 with a 30% carbon fiber fill. It can handle the 250+ degree heat the inlets will see during shut down heatsoak. It is pricey stuff and not the easiest to work with but can be done. That is what I used for my E70 design I am coming out with that I have worked on and off for the past year. The Original N63 had particularly horrible inlets, very restrictive and fragile. Worked out really well, this 11 year old 186k mile engine is now producing X5M competition level hp (stock was 408). You could make some beefy inlets like I did that will never crack and last the lifetime of the engine.

nice! would this fit f85 platform?

[twonb1]

Interested

[mvrt]

Originally Posted by Cbozz

nice! would this fit f85 platform?

just off the pics it seems like a totally different design, IDK too much about n63's but i would imagine the routing is different

[Cbozz]

Originally Posted by mvrt

just off the pics it seems like a totally different design, IDK too much about n63's but i would imagine the routing is different

I think the e70 had a very similar design actually

[Sophisticated Redneck]

Originally Posted by Cbozz

nice! would this fit f85 platform?

Unfortunately no, it is similar but this design is specific for the original n63 in the E70 as the turbo design from that era is different from the S63TU in the F85. I would need to start from scratch for the F85 (3d scan engine compartment, design & run CFD simulations on new inlets, prototype & test fit, flow bench, tweak design as needed, new prototype, tweak again (its always the 3rd prototype that is the home run) then would be ready to produce in mass. Would take about 40-60 hours of R&D to get to that point.

Since mvrt is already underway on development, best let him drive and see what his shop can do for a solution.


mvrt, if your shop doesn't want to produce a solution, let me know and I will get the ball rolling on one.

[mvrt]

Originally Posted by Sophisticated Redneck

Unfortunately no, it is similar but this design is specific for the original n63 in the E70 as the turbo design from that era is different from the S63TU in the F85. I would need to start from scratch for the F85 (3d scan engine compartment, design & run CFD simulations on new inlets, prototype & test fit, flow bench, tweak design as needed, new prototype, tweak again (its always the 3rd prototype that is the home run) then would be ready to produce in mass. Would take about 40-60 hours of R&D to get to that point.

Since mvrt is already underway on development, best let him drive and see what his shop can do for a solution.


mvrt, if your shop doesn't want to produce a solution, let me know and I will get the ball rolling on one.

Will for sure keep you in the loop!

[Chilled]

Originally Posted by Sophisticated Redneck

Titanium inlets would be awesome but trying manufacture the complex design needed for inlets at a decent price point would be an incredible challenge. I would instead look into making them out of a thermoplastic such as nylon6 with a 30% carbon fiber fill. It can handle the 250+ degree heat the inlets will see during shut down heatsoak. It is pricey stuff and not the easiest to work with but can be done. That is what I used for my E70 design I am coming out with that I have worked on and off for the past year. The Original N63 had particularly horrible inlets, very restrictive and fragile. Worked out really well, this 11 year old 186k mile engine is now producing X5M competition level hp (stock was 408). You could make some beefy inlets like I did that will never crack and last the lifetime of the engine.

Hey question, those orange rubber-ish gaskets, are you able to say how they are made/material?

Just been having the idea rolling around in the back of my mind of a doing these as a personal mess-around DIY but drawing a complete blank on how to make those.

No I'm not interested in doing these commercially, all yours.

[Sophisticated Redneck]

Originally Posted by Chilled

Hey question, those orange rubber-ish gaskets, are you able to say how they are made/material?

Just been having the idea rolling around in the back of my mind of a doing these as a personal mess-around DIY but drawing a complete blank on how to make those.

No I'm not interested in doing these commercially, all yours.

Those are actually just the stock BMW seals made for the first gen n63/s63 engines. The S63-TU in the F85 turbo inlets use a O-ring style sealing system.

If you need to print something like that, I would print them out of a TPU filament with around a shore A 70-75 rating. You would need to test how they fare at high temps, the inlets will hit 220-240ish degrees during heat soak after shutdown on a hot summer day. I know TPU does just fine at around 200 but I have not personally tested it higher then that for long durations.

[mvrt]

Just wanted to update everyone, I’ll be able to drop the car off (if the body shop finishes on time) on February 20th for initial measurements and aluminum mock up.

[das1ck1]

Interested

[ture_7]

Im glad to see there are at least 2 of you guys that can do this since aftermarket doesnt feel the need for them.

Whats the update? im surely interested, especially if these come a good price thats not gonna break the bank.

Would you be making these all the way from turbo to air filter in front like the RK intakes? that'd be nice too. Options would be nice.

[mvrt]

Originally Posted by ture_7

Im glad to see there are at least 2 of you guys that can do this since aftermarket doesnt feel the need for them.

Whats the update? im surely interested, especially if these come a good price thats not gonna break the bank.

Would you be making these all the way from turbo to air filter in front like the RK intakes? that'd be nice too. Options would be nice.

Great question!

We have a prototype built out and are zeroing in on a manufacturer with the best price and quality.

Once we build out the first unit I’ll do some testing on my car for QC, and if it’s good to go we will begin pre-orders.

As far as intakes, we have been discussing the option to build out the intake portion as well, similar to RK, but that will likely be in motion once we have the final product for the inlets.

We have a lot more parts in mind to add to the portfolio (including modular exhaust kits that won’t cost $6k+) , it all depends on the interest we generate in this community.

On a side note, I’m also going to be tapping into carbon fiber parts in this upcoming quarter and offer parts nobody else has done yet so stay tuned!

[das1ck1]

Awesome

[mvrt]

Hey y’all,

I know a few of you have reached out asking for updates. Long story short there have been some life events for everyone involved that sort of pushed the process back a bit. The current situation being that the design is finished, previous vendor changed their mind and had set an initial order requirement at 250 units; which, let’s be honest, is a number that is not feasible for such a niche platform. A search for a new vendor is underway and I’ll make sure to update you guys as soon as we lock it in!

[shimmy23]

Originally Posted by mvrt

Hey y’all,

I know a few of you have reached out asking for updates. Long story short there have been some life events for everyone involved that sort of pushed the process back a bit. The current situation being that the design is finished, previous vendor changed their mind and had set an initial order requirement at 250 units; which, let’s be honest, is a number that is not feasible for such a niche platform. A search for a new vendor is underway and I’ll make sure to update you guys as soon as we lock it in!

does this fit the 50i x5? if so maybe we have more folks interested? 50i owner here!

[mvrt]

Originally Posted by shimmy23

does this fit the 50i x5? if so maybe we have more folks interested? 50i owner here!

I can definitely look into it, from my understanding the engine bay configuration is almost identical but I’ve also seen different variations of aftermarket intakes. If anyone else can chime in with concrete info that would be ideal

[Chilled]

Sophisticated Redneck mvrt Guys, any chance you have progressed with the idea of creating metal intake pipe?

Mine (your driver side) has cracked off and am willing to be a guinea pig.

[Djhumvee]

It looks like you could sand down the outside of the compressor housings to put a 2.75 x 3.00 inch silicon elbow, use a 3" carbon or aluminum 45 degree pipe, and a 3.00 x 3.25" silicon coupling, if you don't mind eliminating the PCV connection to the intake like Panda did. This is what I think I am going to do with my n63 to s63 turbo/manifold swap..

[Chilled]

Yeah, buts that's a bit too much damage for my liking. You have to file out that support/ spacing that goes from the flange to the bolt.