BMW F30 N20 Turbo Inlet Flange

UPDATE: I found that the superglue gel didn't hold up for many drive cycles, maybe some sort of epoxy would be better.

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This is a printable flange to replace the turbo inlet flange on the F30 which is usually crumbling and separated from the intake tube due to the adhesive failing. I was doing a turbo waste gate repair and the flange crumbled on me. I didn't have a new intake tube assembly on hand so I quickly modeled this to get the car running while I wait for the part. I was in a hurry so the model isn't 100% perfect, but it's functional. 

I printed it in PETG-CF which is only good for 80c, BMW used plastics with much higher temperature resistance. Polycarbonate would be better but it may be degraded by fuel vapors scavenged from the crankcase. I used Gorilla Glue superglue gel. The injection molded flanges on the OEM intake tube are PBT-GF20 and the formed tube is TPC so whatever material you choose you are glueing it to TPC.

Instructions: Print in the orientation shown in the photos with supports from the build plate turned on, or you can paint on supports depending on how your slicer handles the automatic support generation. 3 walls and 50% infill recommended. 

After printing carefully press the the oval sleeve from the old flange into the new flange. This can be a little difficult. Transfer the rubber gasket to the new flange. Install the flange into the turbo. Degrease and sand the end of the intake tube. Apply gel superglue to the sanded end of the tube and carefully guide intake tube into position and hold it firm against the flange for a couple minutes. Don't attempt to glue it out of the car because the flange won't be clocked properly to the tube. 

BMW PN: 13717605045

Use at your own risk!