2010 Speed 3 Build Diary

So back in October of 2015 a friend of mine worked for a dealership who took in 2010 speed 3, with 60k miles. The car had the FMIC W/ Ram Air Kit from Corksport(CS), a CS turbo back exhaust, HKS SSQV4, CS passenger mount, an upgraded clutch (still have no idea what, all I know is it is very heavy) and some bs tune that had 2-step setup at 2,900 rpms, car was 100% VTA. I had drove stick for the equivalent of maybe 5 miles before purchasing this car, and I stalled it a few times going home.

After getting in touch with some local people, I decided what I needed for the car and so purchasing began.
BNR S4
HTP 3.5" Intake
CS 3.5 bar map sensor
JBR 3 port EBCS
JBR 88-duro RMM
JBR 80-duro PMM
NGK step-colder plugs
Damond EGR delete
V2 Accessport
Autotech HPFP Internals
I started the installation process on a Wednesday night and finished Thursday night, done all in the driveway without taking the manifold off of the car with a few friends. Here is the route to take it out without removing the manifold.
Here is the comparison between the two

And here is the finished product.

Now came the fun part of tuning. We (Mark Gibson) breezed through the 93 octane version of the logging in about 2 weeks worth of time. Then we began to run a 3:1, 93:e85 mix, which came out to e29 right about. Holy shit. E85 is a gift from the gods no doubt. You will see below the difference in my vdyno of 93 v e85 and it is absolutely amazing. Now we could have pushed the 93 harder, but because I am going to be running my e85 mix all of the time, there was no reason to push it.

Here we have the unofficial results of my final vdyno. I say unofficial because Mark will be sending me his vdyno based on my final log though I believe this should be pretty close. My CF is what Mark had set it at, and we used it because it was pretty close to a local dyno. The WT we just determined with me in the car was close to 3500. For anyone who will knit pick either of those 2 variables please see the door. The point of this representation is to show the the curve and difference of the fuel types not the peak numbers. The curves mean more to me than the peak numbers.


I do not have a 1/4 mile time yet, however this Sunday (24th) I will be at IFO in Columbus, Ohio and it will be my first time on the track EVER. I have low expectations honestly, I am just hoping to run in the 13s though I know without slicks I will have lots of spin. This next year I will be working on my driver mod a ton. My 60-100 time using 3 of my most recent e85 logs is right about 5.6 seconds.

So for the future I have some work cut out for me. Unfortunately that small FMIC that comes with the CS Ram Air kit, is not keeping my BATS down. We are starting to see 40-50 over ambient temps. So that plus running out of headroom on fuel, we have to stop here for now. The car feels great and this will hold me over for now. My future builds will come in waves mainly consisting of 3 waves.

Wave 1: Tying up loose ends, to ensure the car can stay at its current power safely.
JBR Trans Mount
Bigger FMIC (thinking TR1035)
Dual OCC setup (using my already bought perm plate)

Wave 2: Stiffening + Better Grip, because the stock 18" are expensive to buy tires for... (Maybe aestethics)
17"x9" Wheels
255/40/17 Tires (unsure about brand yet)
ISC Coilovers
SPC Rear Camber Arms
MAYBE ON THESE LAST TWO (haven't really made up my mind yet)
Strut Tower Brace
2 point Under Brace

Wave 3: Bottom end + Head + MOAR FUEL + Meth + and other various parts
Too many parts to list, however I think it should be known I think I will be going with a relentless ported and polished intake manifold for meth, and going 6th port for fueling. BNR CLAIMS this turbo is close to 500whp capable and I am going to find out.

If you have made it this far then all I have left to say is ditch your OTS tune and get a custom tune. I cannot stress enough how much of a difference it makes for the car PLUS how much you can learn. Just goofing off with the programs and seeing the changes Mark made to my car and how it reacted was eye opening and being this was my first forced induction car, I was definitely glad to have some great people helping me along the way. This is really just the beginning of the S4 and what it is capable of. My block only has 68k on it right now and I am hoping to get the built one in around the 100k mark. So I should have about 2-3 years to get there.

Big things to come for this turd so stay tuned!

EDIT: First time ever at a drag strip

First off holy shit is this car not friendly when launching. I never got a chance to use the 2step because my street tires would have just been blown into oblivion. I was J135 and my first pass of 16.8 @ 104.56, I used no boost in 1st or 2nd. Finally matted it halfway though 3rd. The reason I babied it so much is because on the way to the track my clutch was slipping and I was really concerned it was not going to hold up. My second pass of 15.1 @ 103.72 I matted it from 3rd all the way, but I missed 3rd gear.


My next 2 passes were my best 2 passes of the day. 3rd pass was 14.5 @ 101.66 and I missed 4th gear. At this point I was trying to give it boost in 2nd gear and the torque steer was pretty annoying. The 4th run was my best of the day of 14.4 @ 105.86. Still had tons of wheel hop and plenty of torque steer.

My 5th and final pass of the day if you check the time stamp was shortly after the 4th pass. And a rookie mistake I left the car running almost all hour long between the runs. So my car was heat soaked like crazy. Ran 15.3 @ 106 and I used the flat foot shift from 3rd to 4th that run. Unfortunately my clutch went back to slipping after that and that was the end of my day.


All in all I am pretty happy for my first time ever running at the track. The car is capable of much more, but I need to work on my driver mod and get some better tires/wheels/suspension to help put the power down.

There she sits after her first day at the track. Super excited to get back out and learn more about the car.

 

Small update: As promised here is my official vdyno from Mark. He even formatted it and made it all pretty for me. What a guy. My half-ass 2 minute slap the log in wasn't too far off, but this one is a smoother curve for sure.

 

Looks like high boost doesn't come until 4k rpms. Is this because of the turbo or is it something you asked for in the tune?

 

If he's on stock EM/DP/Exhaust, that could definitely be part of it. I didn't see if he mentioned it in his posts. If I WOT @ 3,000 with my BNR S3, I hit 20psi by 3,250 on my neutered tune.

 

That is because we were tuning for 4k-redline. The car does build boost lower than that.

I did mention the car has the CS TBE in the first paragraph. I am on stock manifold though.

To clear this up, if I mat it @ 3k, I see 20psi before 3,500

 

Good looking curve but i thought you would make more power on the e29 mix. I'm tuning now a similar setup not sure where I'll end up

Sent from my SM-N920P using Tapatalk

 

I didn't see above, did he mention that he has a cat? Even a single, high-flow cat lost me 15whp compared to full catless. YMMV. But I'm also fully bolted/BNR S3'd (though I am v1).

 

We cut power because of my BATs, they are climbing 40+ ambient with my small Corksport FMIC. Since we are building the block there is no reason to push the setup any further. I still have room on my IDC %, not a lot but still some power left on the table.

 

Added my drag times from IFO 2016 in Columbus. Was a super fun event!

 

So Shane, did you get a clutch yet?! Lol

As far as power, the curve is great. Speaking from experience, for those wondering about the peak numbers, Mark will not push a stock block beyond what he feels comfortable, especially for those that use their cars for daily transportation. With the exception of the stock block record car he tuned to 533/436, which ran at that power for 2 years (the owner of that car had a different daily driver, and is meticulous about everything maintenance wise) . When I was on a PTE 5858, from the get go, the goal was always to keep the tq low to preserve the stock block. We finished at 380/350, and I ran that on the stock block til 162k miles until I decided to stop playing with fire and build a motor.

Went built motor and switched to a PTE 5862, he let her rip. Once Shane has a built motor, proper cooling, a good clutch, and fuel, he'll get the powa

 

Just curious: "till 162k miles" from what starting mileage? I've been at ~385/380 since 42k and am at ~68k now.

 

124k. After my motor was pulled, we put it in a locals car, which is running great still, today.

BTW, I bought my car with 25k miles. Ran it on bolt ons and tune til 124k when I got bored and went BT. Motor was abused lol

 

Inspires my confidence
We all know the horror and pucker-inducing nature of zoom, zoom, boom stories. I like stories such as yours as a good counterpoint. Truth be told, the MZR DISI Turbo is a stout engine, when modded, tuned, and driven correctly. I do all that I can to mitigate risk. My power level is considered the upper "safe" limit. I'm FREEKTUNED. I never WOT under 3k in any gear, or under 3,250 in 5th (but only briefly). And I never WOT at all in 6th. I'm hoping for a long-lasting stock block, then building and going for a DD-reliable 450-500whp.

 

Still rocking my really shitty clutch. My vacation is July 2nd, once I come back I need to get the clutch and FMIC hotside piping taken care of. Then I want a bigger IC and moar fuel. At that point I am hoping the research is done for our new (ST) intake manifolds so I can get one for myself.