This is the first time I've posted a car build log on here, but I know there's a fair few M3 fans on the forum so it will hopefully be of interest. I've wanted an E46 for a long time, and when my brother offered me a shell for a reasonable price I snapped his fingers off. We got busy going over the spec for the new engine and eventually a new company was born..
Koflach Engine Developments is a new sister company of Hack Engineering's, which will focus on the development of some very exciting new components for the S54 (to begin with at least). First on the list is cams, but not before a nice engine has been built up to develop and test them in.
The target is a set of cams that push the limits of what can be done while retaining Vanos for road drive-ability - hence 'Fast Road', although they will be equally suited to serious track and race use with or without Vanos. As Vanos can advance and retard the cams by some sixty degrees on the intake and 45 degrees on the exhaust, it opens new challenges.
To be able to tackle this task properly, a development engine was needed - meet KED Build #001. This S54 is destined for my E46 M3 which, despite the extensive development going into the engine, will retain creature comforts and be very much a road car. Air conditioning will be retained and it will even use an SMG transmission.
My E46 M3, seen below, is a 2005 E46 M3 SMG which came into us missing a few bits - the big end went on the engine despite an immaculate service history and so the engine had been removed and various parts of the car had been sold off. However, it sits as a mostly complete M3 ripe for a new engine. It also makes for a perfect test bed!
Part 1
So, here it is. The roots of #001, an S54 engine that was in a very sorry state. A cracked piston around the compression ring land had lead to a rattle - upon disassembly scoring was found on the bore and a new engine was sourced for the vehicle (a 94k mile, 2004 E46 M3). This is where we stepped in, picking up the engine for under £1000 with most of the ancillaries.
A sorry state, but one perfect for what's planned. Upon further disassembly more damage was discovered - nothing that can't be sorted, but a worrying reminder of how fragile S54 bottom end bearings are. These had scuffed the crank and so it will be having a re-grind (sizing TBC).
Crank out and it was time for a quick clean up of the block. It will be going away for boring/honing and chemical cleaning so no need to go crazy here. But we're down to it - a bare S54 ready for some Koflach Engine Developments magic. Hopefully you guys enjoy watching this build progress as much as we will doing it!
![15306790_1879478942282403_1204274555959377920_n.jpg](http://scontent.cdninstagram.com/t51.2885-15/sh0.08/e35/p750x750/15306790_1879478942282403_1204274555959377920_n.jpg?ig_cache_key=MTM5NzIyOTEwNzYzNjU5MzY0NA%3D%3D.2" alt=)
Koflach Engine Developments is a new sister company of Hack Engineering's, which will focus on the development of some very exciting new components for the S54 (to begin with at least). First on the list is cams, but not before a nice engine has been built up to develop and test them in.
The target is a set of cams that push the limits of what can be done while retaining Vanos for road drive-ability - hence 'Fast Road', although they will be equally suited to serious track and race use with or without Vanos. As Vanos can advance and retard the cams by some sixty degrees on the intake and 45 degrees on the exhaust, it opens new challenges.
To be able to tackle this task properly, a development engine was needed - meet KED Build #001. This S54 is destined for my E46 M3 which, despite the extensive development going into the engine, will retain creature comforts and be very much a road car. Air conditioning will be retained and it will even use an SMG transmission.
My E46 M3, seen below, is a 2005 E46 M3 SMG which came into us missing a few bits - the big end went on the engine despite an immaculate service history and so the engine had been removed and various parts of the car had been sold off. However, it sits as a mostly complete M3 ripe for a new engine. It also makes for a perfect test bed!
Part 1
So, here it is. The roots of #001, an S54 engine that was in a very sorry state. A cracked piston around the compression ring land had lead to a rattle - upon disassembly scoring was found on the bore and a new engine was sourced for the vehicle (a 94k mile, 2004 E46 M3). This is where we stepped in, picking up the engine for under £1000 with most of the ancillaries.
A sorry state, but one perfect for what's planned. Upon further disassembly more damage was discovered - nothing that can't be sorted, but a worrying reminder of how fragile S54 bottom end bearings are. These had scuffed the crank and so it will be having a re-grind (sizing TBC).
Crank out and it was time for a quick clean up of the block. It will be going away for boring/honing and chemical cleaning so no need to go crazy here. But we're down to it - a bare S54 ready for some Koflach Engine Developments magic. Hopefully you guys enjoy watching this build progress as much as we will doing it!
![15251817_216100475466277_4626187056379330560_n.jpg](http://scontent.cdninstagram.com/t51.2885-15/s480x480/e35/15251817_216100475466277_4626187056379330560_n.jpg?ig_cache_key=MTM5NzIzMzcxMjQ3OTAxODcyMA%3D%3D.2" style="max-width:100%;)
