Karter16's Silbergrau E46 M3 Journal

[karter16]

Time for an update on the CAD projects.

CAD Project 1: SMG Expansion Tank bracket
I now have a reproduction of the OE bracket that the tank slots into. This is a simplified bracket that doesn't have mounting holes, or the stand off that the original does. That's because I will be mating this to the other part of the bracket that I'm working on. Anyway I'm happy to have this part done. I won't be able to mate the two parts of the bracket together and finalise the part until I actually have the intake in hand so I can ensure everything fits perfectly. So this project will go on ice until then.







CAD Project 2: Adapter for Bosch *101 MAP sensor
And excitingly the adapter for the Bosch 101 MAP sensor is now done! I have a final print in CF-PETG which I will now clean up and bond to the sensor.

Key differences from the last prototype I showed are:
- Return to 1.5mm stand-off. in the CF-PETG 1.5mm is more than strong enough and this allows a bit more of the nose of the sensor to fit into the rail.
- Ever so slightly widened body for better fitment.
- Slight changes to some of the fillets to match the sensor.




And here's some photos of it bolted to the rail (note that it is not bonded to the sensor in these photos). The bolt hardware is temporary just for demonstrating fitment.







I'll be using Loctite 401 to bond the bracket to the sensor. The sensor itself is PBT which can be a bit tricky to bond, however my research suggests that Loctite 401 should be suitable to bond PBT and PETG together (and be heat resistant enough for the application).

I'll post the end result when I have it all sorted.

[karter16]

Recently I picked up a matte screen protector for the headunit. I wanted to give it a go and see if it would be an improvement over the glare that you get from the glossy head-unit screen.

I wasn't able to find one exactly the right size so had to cut to size (which I got wrong slightly as you'll see in the photos). But it's good enough to try it out. If I decide I want to do this permanently I'll pull the head unit out and disassemble it so that I can get the screen protector across the entire surface of the screen so it sits perfectly behind the bezel.

It's quite a big improvement. In the photos below I intentionally didn't clean the surface protector once it was on, so it has my fingerprints all over it. With direct lighting from behind onto the screen this was the most reflection I could get:



And here's a couple of other photos (again with the same lighting conditions but photo taken slightly off-axis.





I'm very happy with this so will try it out in driving conditions over the next few weeks and if I decide I want this permanently I'll pull the unit out and do it properly :-)

[karter16]

Ah ok, technically the connector is 1928403966, just making sure you got all the parts you needed. The kit from 3way even with international shipping is ridiculously cheap, nice find. I'll be ordering from them from now on.

Thanks for double checking - yep I ordered the kit (this one: https://www.3waycomponents.co.uk/pro...it-1928403966/) so it comes with the terminals, etc.

Yeah I live in New Zealand so we get screwed over with shipping on absolutely everything - I think I spent about twice as much time finding the cheapest combination of item cost + shipping for this lot of parts as I did assembling the list of what I needed! 🙈

[George Hill]

Yep 1928403966 is indeed the one I've ordered. (From 3 Way Components in the UK). Like you for the minimal extra cost I'd rather have genuine Bosch.

Ah ok, technically the connector is 1928403966, just making sure you got all the parts you needed. The kit from 3way even with international shipping is ridiculously cheap, nice find. I'll be ordering from them from now on.

[karter16]

Also, the COVID-19 and all of the other kits I found online for the wiring look like they are using replica terminals. I've used them in the past with success but I just found the OE Bosch numbers:
1928403966
1928498056 x3
1928300599 x3

Bought from Chief Enterprises, LLC in Illinois

Yep 1928403966 is indeed the one I've ordered. (From 3 Way Components in the UK). Like you for the minimal extra cost I'd rather have genuine Bosch.


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[karter16]

I just trimmed some material off the nose of the sensor and it fit ok. I did use a larger o-ring (no idea what it was from) and with the larger o-ring the slight misalignment of the mounting bolt hole doesn't really matter, it sits relatively flat. I know you are already going with this adapter and it certainly is going to look cool, just not sure its 100% needed functionally wise.

Also the BMW MAP sensor bolts are to short, you'll need something longer, I used a cam/crank sensor bolt IIRC.

Oh agreed - I think I said a few posts back that you can just trim the nose (and change o-ring) and do it that way. I'm not suggesting this is the only way to do it. I'm making up this adapter just because and because the end result should look nice and tidy.

Haha yes it occurred to me yesterday that the bolts will be too short. I hadn't paid enough attention to what the original CSL sensor looked like and missed that the mounting points were a lot shorter.


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[George Hill]

There is also this version if you want the cool locking feature

My thinking was to get the Bosch terminals, the 966 connector is already hideous enough, lol. Luckily its not visible with the microfilter housing on.

[Slideways]

Also, the COVID-19 and all of the other kits I found online for the wiring look like they are using replica terminals. I've used them in the past with success but I just found the OE Bosch numbers:
1928403966
1928498056 x3
1928300599 x3

Bought from Chief Enterprises, LLC in Illinois

There is also this version if you want the cool locking feature

[George Hill]

Also, the COVID-19 and all of the other kits I found online for the wiring look like they are using replica terminals. I've used them in the past with success but I just found the OE Bosch numbers:
1928403966
1928498056 x3
1928300599 x3

Bought from Chief Enterprises, LLC in Illinois

[George Hill]

I just trimmed some material off the nose of the sensor and it fit ok. I did use a larger o-ring (no idea what it was from) and with the larger o-ring the slight misalignment of the mounting bolt hole doesn't really matter, it sits relatively flat. I know you are already going with this adapter and it certainly is going to look cool, just not sure its 100% needed functionally wise.

Also the BMW MAP sensor bolts are to short, you'll need something longer, I used a cam/crank sensor bolt IIRC.

[karter16]

This evening I also managed to make some progress on...

CAD Project 1: SMG Expansion Tank bracket
With the SMG expansion tank in hand I was able to measure up and design a copy of the bracket that the tank clips into. I measured up the tank:



And was able to draw up the two profiles at the top and bottom of the clip, which results in a bracket looking like this:



Again I've sent it off to Dad to have the first prototype printed.

The second part of this is to 3D scan the strut tower and design up the other part of the bracket - if I get time tomorrow I'll get started on that.

[karter16]

Dad dropped off the the prototype this afternoon:



And here it is fit to the sensor - I'm very happy with how well this fits for a first prototype.






Very happy with how well it fits together and seems I even got the radiuses of the beveled edges right!

It fits up nicely to the rail:




Planned changes for the next iteration:
- Enlarge mounting holes a bit to allow some wiggle room for the mounting bolts
- Enlarge hole for sensor nose as I had to file it out slightly in this proto.
- Reduce the thickness of the spacer plate. The piece is very solid and I think it will be better to reduce it back to approx 1.5mm so that the o-ring on the nose will sit a little bit lower in the air rail.

Dad will also print the next prototype with CF reinforced PETG which should be a suitable end material with sufficient heat resistance for this application. Printing in the target material will allow us to check for any dimensional variance with a different material (proto 1 is just PLA).

I think this should turn out well!

[0-60motorsports]

This is very exciting, you give us hope yet for the CSL air rail folks.

Exactly. Nice one op.
I am tuning OE CSL everything so this is a good backup or shall I even say upgrade

[ugaexploder]

This is very exciting, you give us hope yet for the CSL air rail folks.

[karter16]

The CSL secondary air rail and SMG reservoir were waiting for me when I got home from work this afternoon.

I took the opportunity of having 1 out of 2 children with the grandparents and made a start on...


CAD Project 2: Adapter for Bosch *101 MAP sensor

With the air rail and sensor now in hand I was able to check the fit and measure up:



I was aware that you either have to trim the nozzle or stand off the sensor and that's fine, but I wasn't prepared for this:



Now in practice this probably won't matter too much, but it's not as good a fit as I was expecting.

Also as I had read elsewhere the o-ring will need to be replaced for a correctly fitting item. It's far too loose in this application. If people are buying this sensor and just chucking it on it's not going to be a good seal/fit, there's work to do to make this fit decently.

So I decided to get on with it and draw up the stand-off plate + second mounting point. For reference here are a couple of close-ups of the mounting point on the rail.





And here's some close-ups of the sensor:






And this is the stand-off that we need to account for:



It measures in slightly more than 1.5mm but I'm going to make the standoff 2.5mm thick to allow a little wiggle room.

I knocked this up and have sent it off to Dad to have a first prototype printed for fitment checks:



I'll report back on this when I have the prototype in hand. I expect there will be fine-tuning adjustments to make.