Project R56 Mini @ Riss Racing - Time Attack Forums' Blogs

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Project R56 Mini @ Riss Racing

Project R56 Mini @ Riss Racing

05-12-2009 04:43 PM

Kris@T.A.F. Kris@T.A.F. is offline

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Category: Time Attack Forums' Project Cars

So last Sat I dropped my car off at Riss Racing for some product development. Some of you might have heard of them, but for those of you who havnt they are well know in the BMW 335i market for building some of the highest hp producing parts around. They currently hold the record for the highest HP stock turbo 335i

www.rissracing.com

Well anyway I was talking to them about a catless downpipe that came with a cell fix since there really isnt a catless downpipe for the car except for the Exhaust Depot one and a lot of people seemed to have issues with it. They have the ability to build an electronic cell fix so that will take care of any cell issues

Any way on to the development photos:

Car on the lift:

Looking into intake development:

Downpipe removal:

The last thing I heard from them today was they where gathering materialst today to start mocking up the downpipe and exhaust system.

Ill keep everyone updated as I find out more info.

Update:

Quote:

Originally Posted by Anthony@RissRacing

Ok guys we made some great progress today. I will describe the pics below so you can see in detail the way this stuff is done

Now that we have the downpipe off what we are doing is getting all the measurements for the flanges, piping, etc...

We will need to custom make the turbo flange out of a block of 304 stainless similar too the way we do on the N54. The flange size OEM is 2.75" Putting a 3 inch universal flange on this would be a lot easier & cheaper. However we do not cut corners on design. Since going from 2.75" OEM turbo flange too a 3" universal exhaust flange will cause an imperfection in the exhaust flow.

Now the second part of the OEM DP is there is a smashed section shown in the pics below of two crush points limiting the flow to a little over 2". At the end of the DP it is swedged from a little over 2" to 3" This is so it can mate up too the OEM V-Band clamp. We should have the flange finished tomorrow as you can see we have all the specs set on the Mill today

I will provide all the DP photos + Flange photos below and continue too the 02 Simulator fix we are making on the next post.

5/13/09 - Update:

And a update on the O2 Sim:

Quote:

Originally Posted by Anthony@RissRacing

Ok guys heres the hard part of the downpipes. Right now we are making the 02 Simulator (CEL fix) so you don't have that annoying light or power loss on a catless system. We took the cover off too the DME today and noticed a little bar code placed by the OEM. We have a lot of research too do in regards to making this unit. I have provided a couple pics & will explain in more detail as we get further into it. Thanks!

5/14/09 - Some more updates from Riss Racing:

Quote:

Originally Posted by Anthony@RissRacing

Hello everybody!

Ok so here is the progress through today. I will start with the 02 SIM. This is a decent amount of work. We are looking at both mechanical fixes as well as the SIM fix similar too the N54. To give you an idea of how we go about this...

On a stock car the signal varies between 0.X to 0.X volts. (replacing x with actual numbers for obvious reasons) However once the test pipes are installed the range increases too 0.X - o.X. This extra swing is what induces the catalyst inefficiency limp/code. The 02 SIM reduces the voltage swing back down to stock levels. Done by a voltage divider. (insight on explaining the issue from Shiv @ Vishnu)

THE VOLTAGE DIVIDER:

Basically a voltage divider is created by putting two electrical impedances in series or in our case resistors. It works by reducing voltage at a fixed %. By using Ohm's law we can determine the approximate % based on the resistors that we use.

Unlike BMW we are most likely not going to accomplish this through a pin out version. We will be taping the simulator wires. Where we have left off is we are getting readings from the OEM downpipe then after we finish our downpipe and run the testing we will be able to do the math to determine the fix

and

Quote:

Originally Posted by Anthony@RissRacing

Ok as for the downpipe we were tied up with another project on our tooling so we didn't get a ton accomplished. We did however finalize our measurements & and had the mock up done for the custom flange. We decided to go with 2.75" downpipe to flow exactly with the 2.75" turbo outlet. This will have the best possible flow with no tapers or increases in the exhaust piping. Below are some pics of the process. Depth mic on the turbo to check exact clearance. Measuring angle to get the cleanest bend off the OEM turbo. Once the flange is fully complete. We can cut the pipe tack it together. Swedge the end, and put the 02 bungs in. Were hoping to have it fully finished by tomorrow or mid day Friday. Thanks!

UPDATE 5/20/09

Quote:

Originally Posted by Anthony@RissRacing

Hey guys,

Sorry about the delay on the update. We got the intake manifold off, and are working on an improved design. In regards to taking the manifold off not a very hard job. It is a small space to work so we found it easier to unbolt everything top side. Then lift the car, and get the bottom bracket. Took about 30 - 45 min too take off. Right now we are measuring our room for the manifold + new intake we are making. So this will take another day or two to figure out how to maximize flow. I can tell you this manifold is TINY. The biggest key in manifold design is the runners length. This will determine if we will get more top end or low end by shorter or longer runners. Below are some pics of the OEM manifold off the car. I will update the progress as we proceed. Thanks!

Quote:

Originally Posted by Anthony@RissRacing

Moving on too the Catted downpipes. We finished the cat up. It is a high flow metallic cat. We are working on the piping, and also finished the the end piece. All we need to do is tac it up and add the bungs should be finished by tonight/tomorrow

As for the 02 SIM we have one together. We just need to test it when we finish all of this up with milage testing. If anybody is in the so cal area that would want a set of catless downpipes + 02 SIM let us know via PM maybe we can run the testing on your car since we have Kris's car stripped down.

Update 6/5/09

Catted Production Units:

Heat Coated Catted:

MSRP:

$699 Polished

$729 Coated

http://rissracing.com/alpha/?page_id=3&category=7

Here are the production units:

Catless Polished:

Catless Heat Coated:

MSRP:

$499 on Polished
$529 Coated

http://rissracing.com/alpha/?page_id=3&category=7

Dynos Coming Soon :thumbsup:

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