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      02-28-2012, 01:57 PM   #1
GTM_Challenge
 
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F30 335 / 328 Product Development Begins! - Progress Thread

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CHALLENGE - F30 335 / 328 Product Development Begins! - Progress Thread



Over the weekend we started to tear into our F30 335i sport to see what improvements we can make to the cars power train and other mechanical systems. Naturally, we got her up on a lift so we can give the car a good look over to see what stands out as needing improvement over the stock equipment. We plan on offering a full line of performance and cosmetic enhancements for both the F30 335 and 328i models, with some parts crossing over between the 2 models. F30 M sport and M3 parts will of course follow once the car is released. We took a handful of photos so you guys can see what your new car looks like and have a reference to what we'll be developing moving forward.


Exhaust and Down Pipe ( Cat )

The factory exhaust is actually already a full 3inch unit minus a few small areas where its pinched down a bit here and there. The main restriction point is the rear canister it would seem. The valve system on the canister also help keep it on the quiet side and restricts flow for most of the low to mid RPM range. New on the F30 is the valve system, is now electronic. The previous was a vacuum based system. A bottle style resonator is also used in the mid pipe for keeping sound in check

The F30 now uses a single inlet, single outlet catted down pipe. The E90 N55 used a single in, to dual outlet design. This new design gets rid of the previous unnecessary exhaust split. The cat is typically huge as its the only cat now on the N55. Previous N54 and N55 1 and 3 series used a primary and secondary setup. We should see some nice solid gains once we fit our catless downpipe.












Intercooler

Like the E90 generation car, the F30 uses an aluminum core with plastic end tank design intercooler. There is plenty of room in front of the fans to add another few inches of intercooler core size. We plan to take over this additional space! BMW uses a special clip in style connection at the intercooler hose joints on both sides. We'll be sure to include similar machined edges on our upgraded intercoolers so that stock hosing can be reused with no hassle.




Intake system

The F30 has a relative low restriction intake with a straight path to the drivers headlight area and small ducting that leads to the center grill openings. We'll be looking at ways to maximize the stock configuration, as well as a high flow full replacement in testing.




Oil Cooling

The F30 uses a single passenger side oil cooler stock mounted ahead of the front wheel. The oem bumper has a good sized opening to feed this cooler, but there is room for improvement in the size of the oil cooler core. We'll be exploring a single larger cooler as well as adding a second. We expect the M sport model will also use 2 coolers, or a larger core once released late summer. This has always been an import area for the N54/N55 cars to address for those that want to take the car to the road course.





Just got some of the prototype machined parts for the down pipe and exhaust for the 335 as well as the aluminum ends for the intercooler. These aluminum couplers will allow the use of the OEM special clip in quick connectors for an OEM fit!






We'll be updating this thead with further development and testing photos/videos/dynos. Check back often!

Last edited by GTM_Challenge; 03-23-2012 at 01:46 PM.
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      02-28-2012, 03:25 PM   #2
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Interesting stuff. FYI, I'm pretty sure I've seen pictures of US spec 335i M-sport with 2 oil coolers - one on each side. I think this was the only reason to not have the fog lights. It would be interesting to see if the 328i M-sport has also two oil coolers.
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      02-28-2012, 04:13 PM   #3
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very cool.
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      02-28-2012, 04:16 PM   #4
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very interesting. Thanks for the share
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      02-28-2012, 05:22 PM   #5
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Cool stuff! Looking forward for more info you guys can provide.
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      02-28-2012, 05:27 PM   #6
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You guys ever take something apart and then say "A-oh, how do I put this back together now?" That's my biggest fear.
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      02-28-2012, 06:05 PM   #7
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Quote:
Originally Posted by JoeyO View Post
You guys ever take something apart and then say "A-oh, how do I put this back together now?" That's my biggest fear.
HAHA. When we take the cars apart, we always bag the bolts and label them so we know where everything goes and nothing gets lost
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      02-28-2012, 06:16 PM   #8
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I notice the horns are now on each side of the front bumpers... instead of having two on one side or botn in the middle as in the past...
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      02-28-2012, 06:56 PM   #9
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horn is def louder than e90
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      02-28-2012, 11:11 PM   #10
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I'm looking forward to seeing what you guys come out with.

Where did you dyno at? I am looking for a quality dynojet location here in IL.
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      03-01-2012, 08:38 PM   #11
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Quote:
Originally Posted by flipm3 View Post
I'm looking forward to seeing what you guys come out with.

Where did you dyno at? I am looking for a quality dynojet location here in IL.
Sent you a PM
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      03-02-2012, 02:47 AM   #12
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      03-02-2012, 10:41 PM   #13
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Looks like we'll have the first test exhaust done tomorrow to test over the next week or so.

We'll be sure to post some photos and clips once we have something to share, and once weather allows. Stupid snow
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      03-02-2012, 10:46 PM   #14
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Challenge F30 Blackout Grill and Whisker Kit going on tomorrow along with painted reflectors. Body color option grills and whisker images coming soon too.



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      03-06-2012, 07:27 PM   #15
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We should be posting installed pics tomorrow as long as the rain holds off and we can wash the car here in some warmth We'll sneak in some shots of the test exhaust too...
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      03-08-2012, 08:36 PM   #16
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We managed to get the car washed up today and catch a little sunlight with the blackout painted grills and whiskers as well as the painted side markers. Looks MUCH better





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      03-09-2012, 12:17 AM   #17
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looks great! how hard was it to swap out the painted reflectors? i heard it is harder than the E9X's.
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      03-09-2012, 01:21 AM   #18
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Nice!
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      03-09-2012, 12:05 PM   #19
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looks great! how hard was it to swap out the painted reflectors? i heard it is harder than the E9X's.
It's not too bad. just have to pull the fender liners back. if you have a heat gun or hair dryer, you can probably push it from the front and support the bumper from the back to break the 3m tape seal. Its easiest if you removed the bumper so you can get the old tape off best.
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      03-12-2012, 04:13 PM   #20
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So it looks like the 328 exhaust is exactly the same underneath the vehicle as the 335 except the 335 has one pipe coming out each end as opposed to just one on the drivers side. It looks to be the same size and same mounting position.
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      03-12-2012, 05:21 PM   #21
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Quote:
Originally Posted by kbuys View Post
So it looks like the 328 exhaust is exactly the same underneath the vehicle as the 335 except the 335 has one pipe coming out each end as opposed to just one on the drivers side. It looks to be the same size and same mounting position.
I have the same thoughts as well, but i think there may end up being some differences. Once we have a 328 to take apart here we'll be able to chime in more.
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      03-12-2012, 05:26 PM   #22
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We have been testing our catback for the F30 335 over the past week. We are playing with some different canisters to get the right amount of sporty sound with no droning or excessive noise. The exhaust will used full 3in piping front to rear ( the OEM pinches down to 2.5in in the front areas) with a dual outlet canister and 3.5in exhaust tips Once we add the catless downpipe, it'll add some more aggressive sound as well as a good bump in power im sure

Here are a few shots we took the other day once the weather cleared up a bit. We'll take some more shots of the exhaust once we have a more finalized version to show.








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