2nd Gen R60 Countryman Countryman All4 - Engine bay modifications

Discussion in '2nd Generation: 2007+ R55 through R61' started by AWD_Rally, Jul 6, 2015.

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  1. AWD_Rally

    AWD_Rally Member

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    #1 AWD_Rally, Jul 6, 2015
    Did some trimming to the cowl. Plan is to use the area where the battery is. once I relocate the battery to the rear of the car. I attempted to do a WRC style cowl. I also sealed the front of the hood area better.

    Engine bay now
    20150706_163450_zpsbghw6pfc.jpg

    Before engine bay for reference
    20150617_145656_zpsvkilebsn.jpg

    New front hood sealing
    20150706_163852_zpsyv8a2wxu.jpg

    WRC engine bay :p
    MINI-John-Cooper-Works-WRC-Video1_zps32u4peg6.jpg


    I still have a few things to do before the engine bay is done. The area where the battery is currently sitting is where I will most likely put the coolant tank. Maybe the OCC, if it fits too.

    I need to:
    Finish the final version of the CAI intake (w/heat shielding)
    Relocate/replace OE coolant reservoir tank
    Relocate the battery to the boot
    Weld strut bar together
     
  2. AWD_Rally

    AWD_Rally Member

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    #2 AWD_Rally, Jul 10, 2015
    I spy, with my eye, a lightweight battery made by Shorai.

    20150710_141540_zpsar03yy42.jpg
     
  3. AWD_Rally

    AWD_Rally Member

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    #3 AWD_Rally, Jul 17, 2015
    Did a resistor mod today to the plugs that go into the PCV hoses. I did that to fit my custom CAI in there without having to worry about retaining those plugs.

    20150717_121740_zpsffbjz2m1.jpg

    1k ohm per plug. Secured out of the way.
    20150717_121748_zpstw8ajwkz.jpg

    CAI prototype I'll be finishing up soon to install.
    20150709_172417_zpsfvadrt91.jpg
     
  4. bintliff25

    bintliff25 New Member

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    #4 bintliff25, Aug 1, 2015
    Last edited: Aug 1, 2015
    Interesting Idea, I needed all the emission stuff (unfortunately). But I like your Idea, I thought why add all the piping and curves. Find the shortest route. I believe it could be done with only one bend. two silicon hoses, have all the connections relocated.
    Silicon hose/air intake to turbo (see below), 90 degree pipe bend (steel,alum, etc hard to not collapse, bend. Small piece silicon hose to connect MAF and air filter to MAF.
    (Silicon hose/air intake to turbo)
    [ame=http://www.ebay.com/itm/GPLUS-SILICONE-INTAKE-BOOST-HOSE-FIT-FOR-BMW-Mini-Cooper-S-R60-2011-2015-BK-/251295755565?hash=item3a8264ed2d&vxp=mtr]Gplus Silicone Intake Boost Hose Fit for BMW Mini Cooper s R60 2011 2015 BK | eBay[/ame]
    a thermal barrier (flexible sheet/roll to create a wall) isolating the filter from the MAF to make a true CAI.
    I test fit most of the items, and plan on using an ALTA foam filter with a pre screen filter for water. looks to fit with room to spare. Just need to buy the Silicon hose turbo to air intake hose (pictured).
     
  5. bintliff25

    bintliff25 New Member

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    #5 bintliff25, Aug 1, 2015
    Last edited: Aug 1, 2015
    All items to make this are leftover from other projects, Except the Turbo air intake hose.
     
  6. AWD_Rally

    AWD_Rally Member

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    #6 AWD_Rally, Aug 2, 2015
    The maf needs a certain amount of room/pipe length post maf. Your idea was my original idea. The reason i went this route was because im looking for a plug and play for people without the need of an expensive tune. Jb+, install and go.

    Everything is reversible with my setup, which is why I used resistors instead of completely deleting it. Not saying what i have is the best idea, but a lot of research has been involved.

    Now, if a mafless tune comes out, i want the shortest route humanly possible. Ha.

    If you do do it, let us know how it turns out!
     
  7. AWD_Rally

    AWD_Rally Member

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    #7 AWD_Rally, Apr 8, 2017
    50mm turbo arrived...

    OE 37mm Turbo
    [​IMG]

    [​IMG]

    50mm
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    [​IMG]

    [​IMG]

    [​IMG]

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    [​IMG]

    OE 37mm turbo vs 50mm turbo

    [​IMG]

    [​IMG]

    [​IMG]

    I have some work to do now to get my custom setup all finished up.

    1) I have an aluminum cold side charge pipe that I'm going to weld a recirculation valve connection on; I'll then block off the OE location for the BV on the turbo.
    2) I want to relocated my battery to the cabin so I can move the coolant overflow tank and occ in the area the battery is currently in... so that I can make room for my custom cold air intake.
    3) My CAI will have a box to make it a true cold air setup. Still need to get all that fabricated.
    4) I want to get my head ported to flow amazing... and forge the internals.
    5) Finally, I want to port, polish and ceramic coat the exhaust manifold and turbine housing.

    Shooting for 350HP on pump gas. The car is currently sitting at 2980lbs (stock is roughly 3220lbs), I'm also looking to drop about another 100lbs off the car when I'm done with this setup.
     
  8. 00Mini

    00Mini Well-Known Member

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    #8 00Mini, Apr 8, 2017
    Very interesting project !!
     
  9. eMINIparts

    eMINIparts Well-Known Member
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    #9 eMINIparts, Apr 10, 2017
    More please....Cant wait to see the next update...:popcorn:
     
  10. AWD_Rally

    AWD_Rally Member

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    #10 AWD_Rally, Jun 12, 2018
    Been slightly delayed, but still moving forward with everything. I started a company last year so the car has been on hold.

    I'll be back...
     
  11. MCS02

    MCS02 Moderator
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    #11 MCS02, Jun 13, 2018
    Get to work on the car slacker!:D
     
  12. Sully

    Sully Administrator
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    #12 Sully, Jun 13, 2018
    Congratulations on the new company... can't wait to see more of this build. :D
     
  13. Goldsmithy

    Goldsmithy MINI Alliance Ambassador
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    #13 Goldsmithy, Jun 13, 2018
    Very impressive and well thought out...especially using 'stuff' you had around. :) Wish I were that talented...
     
  14. Sully

    Sully Administrator
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    #14 Sully, Jun 18, 2018
    Not sure why I just picked this up.. in the pic's he is clearly using the Home Depot black/yellow boxes. I have a ton of those bad boys for the RZR's. Great storage devices. Strange what the eye pics up when looking at a Turbo taken apart. :Bag:
     

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