BMW 645Ci E63 with 542bhp! BUT there is a catch!!! ESS G1 Supercharger episode 4

We made a smaller pulley. increased boost by 2psi. Made 542bhp but gearbox cant take it! It's faster at 514bhp! Now you know!
How we got to 514bhp here • BMW 645Ci E63 with 514...
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[@ilyakrylov4081]

there are more videos in the series if you want to check them out. kzbin.info/aero/PLlD0kh0mRmTlby_5lpUEo7A9UeZl4_Ta8

[@blakeamathews10]

Just got a 05 645 couple days ago. Already have ESS saved on my homescreen 😂 glad I got the manual transmission, 550 is in my future 😁

[@scootitnbootit9231]

The ZF 6HP26 gearbox in your car is very robust and can handle much more power than 500 hp. It more than likely is overdue for a servicing, which absolutely matters with these gearboxes. They need all of the mechatronics seals replaced as well as a fluid and filter change every 50k miles. It can handle the power so long as it can keep up proper valve body pressure. There is a big following for these gearboxes here in the states. If I can be of any assistance, feel free to message me. I’ve rebuilt a few valve bodies on this transmission before and it’s really not too difficult.

[@RuskiWeldFab]

thats some good info! I am sure Connor will be back to comment

[@MrConnorHorton]

The issue is the line pressure. The ecu torque map ends at 600nm. After that the gearbox sees -100nm. We’ve got the TCU seeing around 580nm now and it holds 540ish but can’t hold 577 which the car has made since. The gearbox has been completely rebuilt. I also now have ghe exedy 1000hp rated clutches that I’ll build into my sister gearbox but not for a while yet.

[@scootitnbootit9231]

@@MrConnorHorton Gotcha, thanks for the insight. I’m fixing to have to rebuild my 6hp28, I’m getting ratio monitoring fault codes, causing the 3rd gear lockup malfunction. I’ve done the valve body but it seems I’m going to have to tackle the internals. 🥲 So this is your car? It’s a sweet ride man. Tell me, why’d you go with the M5 diff instead of a quaife? Are you still happy with the supercharger kit? I’ve been itching for a while now to pull the trigger and get it.

[@MrConnorHorton]

@@scootitnbootit9231 it’s my car yes mate Still going fine. It’s currently around 520-540 ish and the gearbox see 580nm ish. That’s enough for it to hold for now. Once I’ve built the other gearbox I’ll go for more power again but not until next year now. Aside from the gearbox it’s been fine. The m6 LSD is really really good. My old boss had a m6 so I knew it was good before I did it.

[@brockhayes8774]

500bhp was the limit for my transmission. I simply swapped out the stock transmission with one sourced from an ALPINA B7. Theres a little bit of a modification (mechatronics swap and gear selector prindle). But she runs like a top.

[@RuskiWeldFab]

That’s good to know! Cheers

[@MrConnorHorton]

@Eggert Eggertsson it’s a m6 diff. You need e46 stub axles, the rear half of a m6 prop shaft and the m6 LSD. It’ll go straight in. And just a little 1mm sleeve for the rear mount bolt.

[@superbee1m]

Awesome work guys, I'm getting ready to supercharge my 2010 650i right after I paint it. I'll be doing the paint and the ESS install myself and it's good to have your videos to fall back on in case I get stuck.

[@Gemotogen]

Bro I want too make my n62b48 with supercharger, but our with you engines have very high compression ratio. I can give a link to a Russian site where a compressor from Alpina was installed on the b48, if you want.

[@bikevideo1]

Good work boys, loving it so far.

[@RuskiWeldFab]

thank you! its not like it was slow to begin with.. haha

[@Carls_Built]

Glad Australia & NZ aren't the only one's to bag out US-HP hahaha Damn nice work on that pulley too!!

[@RuskiWeldFab]

Thanks! But you lads all in to KW haha. Pulley I made is no more haha

[@nickschaefer77]

Did you have to make changes to the Crankshaft or the Rods? I've read a lot of times, that a supercharger on the N62 won't work with the stock compression of 10.5:1 How is this setup for a daily driver?? Nice videos by the way ;)

[@RuskiWeldFab]

Nope, engine is stock as far as i know. and thank you!

[@MrConnorHorton]

Yep all stock internally. 10.5:1 compression is fine for boost these days. Tuning has come a long way.

[@rafalbosowski7301]

Where did you get the supercharger kit?

[@RuskiWeldFab]

Merica! fuck yeah!

[@pathipank6280]

You could go with 6hp30 from 740d it can handle 750nm.

[@patrykanonim289]

Well done, can you expect bigger gains in n62b48?

[@RuskiWeldFab]

no idea. its all very individual!

[@Gemotogen]

Здарова брат, в б48 проблема в степени сжатия и толщины стенок цилиндров , на б48 и без того большая степень сжатия , почти 11 очков , стоит нормально дунуть , поршневой можно сказать пока.

[@burton686spy]

You'd need a smaller belt with the smaller pulley

[@RuskiWeldFab]

and send it!

[@b2bogxxy]

I'm building from scrach same project.. my car is manual.. regarding gearbox .. use a diesel 6hp28 keeps up to 1100nm.

[@RuskiWeldFab]

Great. Thanks for the tip. And good luck!

[@MrConnorHorton]

The diesel gearbox won’t be any better. It’s not so much that the box can’t take it it’s the fact that the ECU is telling the TCU the car is only making 440nm of torque. If I put a diesel box in the ecu will just tell it the car is making less torque and it will lower the clamping force values accordingly. The ecu tuner thinks he can up the data values sent from the ECU to the TCU but it’ll depend if the provisions for the upped values are loaded into all the TCU systems or if they are specific to each vehicle. We will find out i suppose

[@b2bogxxy]

@@MrConnorHorton What you say is explaoned here kzbin.info/www/bejne/nobOq5Jjh5Wdatk It works , you just need to align dme ecu with gearbox ecu

[@MrConnorHorton]

@@b2bogxxy I just watched the whole video. That’s that’s exactly as we thought. Very good video.

[@wildrico6656]

How can I purchase a ESS supercharger for my 645ci ?

[@RuskiWeldFab]

i think you can start by going to their website and try find a dealer?

[@alexwalsh31]

You can get 2nd had DCT for around £2,000 to £2,500

[@reginaldbowls7180]

Does anyone know if the manual trans has the same HP/TRQ limit?

[@RuskiWeldFab]

Manual wouldnt have any such limits.

[@powpow4033]

how much did the kit cost?

[@RuskiWeldFab]

wont have much change from 10k

[@nicknicusor6952]

50 mile 🤣🤣😂😂😂

[@Peregovorchik]

Dragy 100-200?

[@crazydizel]

Норм валит) а как называется такой компрессор, это типо турбина но с механическим приводом? Смотрел с автоматическими субтитрами это боль конечно)

[@RuskiWeldFab]

валит мама не горюй! центробежный нагнетатель. как турба только с ременным приводом

[@RuskiWeldFab]

субтитры совсем боль? 😂

[@crazydizel]

@@RuskiWeldFab я так понял это автоматические) гугл переводчик xD

[@RuskiWeldFab]

Да но не через гугол. Но получается тоже самое. Вроде смысл доносит

[@crazydizel]

@@RuskiWeldFab Угу понять смысл можно)

[@chungus_khan]

Would sourcing the trans from a wrecked E65 chassis Alpina B7 (supercharged n62) be feasible?

[@RuskiWeldFab]

only one way to find out lol. but where to find one for reasonable money?

[@chungus_khan]

@@RuskiWeldFab eek, maybe an auction? insurance company...? body shop? sometimes people bite off more than they can chew when purchasing a supercharged B7, the air suspension sags, & folks end up letting them sit. They take 'em to the shop for repairs, & freak out over the cost & decide to sell them as-is. Might have to do some scouring - they were rare. But if ya could find one, it'd be pretty sweet!

[@chungus_khan]

@@RuskiWeldFab The Merc, say, E320 had their 722.6 5AT - the E55 AMG also had the 722.6 5AT, but had a beefed up valve body, shift solenoids, & torque converter lock up solenoids - maybe, maybe you could source the supercharged B7's shift solenoids, tq converter solenoids, & valve body...🤔

[@MrConnorHorton]

It’s the software that’s the issue not the box. I think we’re nearly there with it

[@Projektphotos]

Whats the cause of slipping in the trans bc im having the same issue with mine and my car is stock.

[@RuskiWeldFab]

the ECU thinks it still has 440nm.

[@MrConnorHorton]

Your stock one shouldn’t slip. Your gearbox needs a rebuild. This has since completely ruined the gearbox and has been fully rebuilt but I’m still chasing issues with the gearbox software

[@Boosted_e63chuck]

How much of a gain were you able to get from just the water/meth injection?

[@MrConnorHorton]

Without the charger ? Nothing

[@Niihadd]

Hast du mit dem serien riehmenscheibe weniger leistung gehabt nir 447ps? Wie geht das?

[@RuskiWeldFab]

sorry dont speak german my friend.

[@Niihadd]

@@RuskiWeldFab oke i dont spek english good... Oke you have with stok ess puley(biger) only 447hp? And with smaley pully more hp? Why this?

[@RuskiWeldFab]

smaller pulley makes more boost because it spins faster.

[@Niihadd]

@@RuskiWeldFab okey good information and whats is with intercoller you need it? An the (stok) engine have dont problems with 500 hp?

[@Niihadd]

@@RuskiWeldFab i have a bmw 650i e63.. And i only find the G1 kit for bmw 645i. But i think this is one to one mehanics. Only a good tuner make mi a software?

[@tonytony6018]

Hi I have a 545 project with another supercharged Is it possible to get a map with which comes supercharged If of course you want to give it to me Thanks

[@RuskiWeldFab]

it doesnt work like that lol. your map will be totally diffrent.

[@tonytony6018]

@@RuskiWeldFab I think he can only start the car If I have these settings then I will set it for mine

[@tonytony6018]

@@RuskiWeldFab If you have a Facebook, I can show you photos from my project

[@MrConnorHorton]

Hi Tony. My car has ESS map on it which is encrypted to the car the first time you use it. The piggyback ecu then tunes the values of the ESS map. So I can’t take anything off for you I’m afraid. Also no way would my tuner allow that.

[@tonytony6018]

@@MrConnorHorton no problem Thanks

[@Tehkkey]

Did you guys replace the valve stem seals, head gasket, or any other big maintenance item before installing this G1 Supercharger? I'm wanting to buy the TVS2 Supercharger but want to do all the maintenance that way I have the least chance to blow my engine up. I know, I could just sell the 545i, buy an M5 and already be at the HP I'd make from supercharged N62, but building is about the journey, not the destination. Besides, I've put too much restoration maintenance into this 545i to just let it go.

[@MrConnorHorton]

Yes mate I did all of that. Everything has been refreshed or replaced…and i mean everything on this bastard.

[@Tehkkey]

@@MrConnorHorton hells yeah! Well I respect the grind and the build, good job!

[@jamescarroll8972]

I think supercharging the 545i would be cheaper if you got the 545i for under 5k

[@Tehkkey]

​@jamescarroll8972 what if I got it for exactly 5k? 😅

[@acourtneylawson2065]

I have two e65s with 4.4l...been looking for a supercharger at a reasonable price...which would be the best route to go....there’s not much on the market for these engines...wanting at least 400+ hp??

[@RuskiWeldFab]

charger if you want lots of power

[@MrConnorHorton]

Define reasonable price

[@acourtneylawson2065]

@@MrConnorHorton 🤣....I cant...I’ll just say estimate??

[@MrConnorHorton]

Your not getting 400hp without a supercharger ever. So 8k ish.

[@acourtneylawson2065]

@@MrConnorHorton good info...I was thinking about an ls swap...but if the internals don’t need upgrading I’ll look into supercharging...what’s your opinion??

[@albundy6509]

Can I use this supercharger System on a e60 550i with the n62b48 engine? I hava a 550i e60 enigne is new rebuild! But i have a six speed manuel Transmission! Is the ess kit expensive?

[@MrConnorHorton]

Check the ESS website for prices. They do a kit for the b48.

[@bradleykindell]

The kit for the N62B48 engine is the same as the 4.4 one. It's not listed by ESS as there is one difference and they can't get the part needed, but it's an easy DIY to work around. Apparently one of the coolant hoses needs to be reworked to fit this to the 4.8 engine. Also, I think the oil cooler pipes need to be moved slightly. (4.4 engine doesn't have oil cooler)

[@andylaunchbury8539]

That poor car! 😂is it a dct gearbox in that model?

[@MrConnorHorton]

Na it’s the ZF6HP26 auto box. It’s been remapped for true manual and paddle shift. So it holds whatever gear I want and won’t upshift at the limiter

[@andylaunchbury8539]

@@MrConnorHorton ah ok gotcha. Thanks. Any way to beef them up to take more power?

[@RuskiWeldFab]

We working on it! I just need. Bigger lathe 😂😂

[@MrConnorHorton]

@@andylaunchbury8539 it can take the power I just need to find a way to up the line pressure. As far as the gearbox ecu is concerned the car is making 440nm where as it’s actually making 620nm. The gearbox just doesn’t know how hard to clamp the clutches.

[@ReMaQs]

​@@MrConnorHorton Remapped thru XHP flashtool?

[@munichstall]

Зачет, и какое примерно давление на шкиве в 514 сил?

[@RuskiWeldFab]

7psi

[@munichstall]

@@RuskiWeldFab нехилая такая прибавка) Коллектор бы с жидкостным охлаждением и через фреон😂

[@RuskiWeldFab]

Ну да валит 🤪. И так на метаноле для охлаждения

[@munichstall]

@@RuskiWeldFab Лить его гемор, сами на метаноле гоняем, бывает в неподходящий момент заканчивается🤣

[@RuskiWeldFab]

@@munichstall это да есть проблемка в этом. Тут бак на 5Л. Всеравно маловато

[@blertonselimi2457]

hallo kannst du bitte mal video machen mit 100-200 zeiten

[@RuskiWeldFab]

one day we will yes.

[@albundy6509]

100-200kmh? Please...

[@user-md4es4yk6f]

what's gonna happen if you drink that methanol?

[@RuskiWeldFab]

you get high. not advisable

[@TheVassilek]

This CAR ISN"T LOUD !! My 545i its 5 times louder :D

[@Mikey_Chopps]

Geesuz christ, use the proper freakin tools you shade trees.

[@RuskiWeldFab]

😂