On November 5th, 2021 we finished up a 600whp 330i turbo setup.
We first began by doing a few baseline pulls to check over fueling, ignition timing, etc. Our initial pull is indicated by the red line shown above, which was at about 15psi with a conservative base map. We tuned this car entirely on the stock MS43 ecu. After rescaling the entire tune as we had maxed out engine load at about 450whp with this particular setup, we began running through different boost settings. Slowly increasing our boost and watching fuel and ignition compensation and adjusting the curves of both as needed.
We adjusted the cams to maintain power a bit better up top.

At about 20psi, we began to spin the tires on the dyno and experienced spark blowout. We tightened down the 3 rear straps even more, replaced spark plugs with a bit tighter gap, and we kept on going. At this point, we were making in the mid 500rwhp and ran into a few boost cuts as we configured the GFB boost controller.
At this point, we were seeing a lot of torque really early, so we readjusted our timing curve and made a few adjustments to try and mitigate our torque delivery.

At 25psi, the boost reference line for the boost controller shot off the M50 Intake Manifold so, that went back on, and clamped down. We continued on till about 28-29 psi as everything was looking pretty good. Ran into some spark blowout at 29psi, along with some boost cut. We turned the car down to 28 psi. It just needed a bit tighter gap again at this boost level and she was all clear. Stock pencil coils held up perfectly.
This customers car was still using the stock fuel pressure regulator with Bosch 1000cc injectors and a single Walbro 450. We ran out of injector at this point. Reconfiguration of the fuel system will be done to meet our fuel requirements a bit more happily. Don't think for a second that this car won't be beat on at this power level, oh because it will! If someone were to repeat this setup, we would recommend beefing up the fuel system a bit to cope with the fuel demands a bit better.

This engine was semi built and the builders for some reasons decided to leave stock rods in it, so, we did what we could.

Given the setup, we had to run a bit more boost than expected at 28psi, but it wasn’t too bad. The turbo did not seem out of its efficiency and was making heaps of power with small boost changes. Using an ascending ignition curve to control torque and power output, and optimize cam angles to hold power a bit better up top, we really enjoyed how well this car behaved. This was probably one of the most cost effective builds at this power level, using qualities part where needed, and "okay" part where they could.
This just goes to show how capable the M54 engine family is. It doesn't generally get much love but, with the right attention and the right tuner (like us :)) you can have a very capable and reliable car. 600rwph on an E46 is not a record, it has been done before a few times... BUT, it is not done often, especially not with a dyno to back it up. So, it is a feat to be proud of nonetheless.

We are happy with how we were able to develop the curve given the power goals. Our tune is set up to allow for some boost compensation so the owner can vary the boost level (though this doesn't always apply to all builds).
Now it is time to see how well the stock rods last!!

Red line on the dyno graph indicates our first baseline run.

Blue line is one of the final pulls at 28psi.

Specs as follow:
M54B30
M12 Headstuds
Cometic Head Gasket
9.5:1 CP Pistons
Stock Rods
2.5” Charge Pipes
Mishimoto 3” Intercooler
3” Downpipe
Bosch 1000cc Injectors
Walbro 450
China GTX3582R
M50 Intake Manifold
China Cast Manifold
PMAS HPX MAF
E85🌽