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  1. #26
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    Components:

    Components:

    Click here to enlarge

    (description from the RE product website)

    A. 6061-T6 ACQ Billet Carrier - Painstakingly CNC machined from a block of aluminum about the size of a brick, this carrier has incredible strength and rigidity over a stock component. It incorporates Rogue Engineering's Pivot Relocation Cup, to raise the pivot point of the shifter higher, allowing the shifter more drivetrain clearance. For additinoal strength, the rear of the carrier has a steel spike to secure to the mounting point of the vehicle. An important feature is that it realigns the selector rod so that it is near the factory position, preventing off-axis forces against the transmission's selector rod gear joint, preventing shifting notchiness. If you wonder why Rogue Engineering's shifters have always been the SMOOTHEST shifters on the market, this is one of many small details which allow many of our customers to recognize the ingenuity of RE OCTANE SSKs.

    B. Our OCTANE shifter lever may seem like the same lever we use in our other kits, but at a closer glance, you will see that it incorporates a double bend, to emulate the factory shifter lever. In essence, the top of the factory lever is moved backwards, approximately 1/2 from the axis of the lower part of the shifter. Other companies have made the mistake of only bending the top of another factory lever backwards, hoping to solve this ergonomic challenge. However, bending the top of the lever back only tips the shift knob towards the driver, and does not emulate the factory position accurately.

    C. Rogue Engineering's Self-Adjusting Pivot Point (SAPP) is still used in our E9X M3 application, proving that our simple and effective method of lower pivot tension control maintains reliability, durability, and longevity. Just ask the 50% of the Grand Am Koni Challenge teams racing with Rogue Engineering shifters in their cars.

    D. We replace the hollow, factory selector rod with a heavier, TIG welded, stainless steel replacement. This adds additional mass, over the press-tube construction of the factory part. This helps the shifts in the vehicle feel factory smooth, while allowing for the reduced throws. Our weighted selector rod is twice the mass of the factory part (factory is 120g, ours is 245g).

    E. We use factory replacement pivot cups and locking circlips to secure the shifter together. These are the same components used in all current model BMWs.

    Let's begin:

    1. Start by pulling off the shifter boot (pulls upward)

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    2. Gripping tight on the shifter knob - pull upward. Be sure to keep your face and sunroof (if equipped) out of reach as this can be potentially dangerous when pulled free

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    3. Disconnect shifter illumination connector

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    4. The insulating foam will need to be removed next, this can be pulled free from the shifter console while allowing the console to remain in place

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    Foam insulator removed

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    5. Lift vehicle or raise on jackstands

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    6. Remove skid plate and transmission felt liner

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    7. Unplug O2 sensors from catalytic converters (4 total)

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    8. Remove felt skidplate from bumper

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    9. Remove exhaust brackets/hangers

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    10. Remove band clamps from after resonators

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    11. Exhaust section coming down

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    12. Exhaust removed for easier access to shifter

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  2. #27
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    13. Heat shielding is to be removed next to access driveline assembly

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    14. Start by removing all small screws that hold on shielding

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    Image of Guibo and bottomside of stock shifter assembly

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    15. Remove transmission carrier assembly and driveline mount, transmission will drop slightly downward to allow additional clearance to shifter assembly

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    16. Remove retaining clips on selector rod (1 on each side) and shifter assembly (total of 2) with a using a pick tool.

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    17. Preparing for driveshaft removal (optional, but allows additional clearance)

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    Driveshaft mark for proper alignment when reinstalling

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    18. Free pin bushing from undercarriage using a small screwdriver to work the bushing out of place, being careful not to bend the metal around it.

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    19. Remove shifter from vehicle.

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    20. Transfer rubber from stock shifter to new RE shifter

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  3. #28
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    AP Racing Strap Drive Systems

    Next on the list was brakes.

    We've always been a big fan of AP Racing BBK systems. AP Racing brake discs are made from the highest quality cast iron. Curved vane technology is used to shed internal heat, and the optimized cross-drilled and slotted face pattern is developed to increase pad bite and improve cooling. Each hole is radiused, not chamfered, to reduce noise and increase fatigue strength.

    The new 7100/7150 AP kits were also designed to fit behind stock 18" wheels and clear without the need for spacers, which is an added plus when our M3 starts seeing more track use.

    The AP Racing engineers are the same ones who manufacture the OE brakes for Ascari, Aston Martin, Bugatti, Caparo, Farbio, GTA, Holden HSV, Koenigsegg, Lotus, McLaren, Morgan, Noble, Pagani, Rossion, Seat, Spyker, Tramontana, Ultima, Zolfe and other limited, high-end exotic supercars.

    Strap Drive Systems

    The Strap Drive System (Patent Pending) has been developed by AP Racing both for Road and Race applications. The standard fitment discs on many performance cars can suffer from brake vibrations caused by disc distortion. This generally occurs on fast road and track installations.

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    On many performance cars the typical standard disc will be a heavy duty ventilated single piece casting. Couple this type of rigid disc to a standard hub and wheel bearing and the result is any hub distortion / run out will transfer onto the disc brake faces. This eventually results in brake vibrations, usually picked up through the steering wheel.

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    The strap drive system offers a new take on the floating systems already in the market place. Strap drive uses a series of stainless steel straps to locate the disc to the mounting bell, producing a flexible coupling between the hub and the disc faces. This allows the disc to run true in the caliper under all conditions and also permits the disc to expand and contract without being restricted. Some current replacement discs in the market place have evolved from Motorsport applications, they typically use a drive bobbin to provide some disc float and were devised to reduce pad knock off on race cars. This system can work on a road application but there are some major drawbacks that the Strap Drive has overcome with its simplicity.

    Bobbin float discs rely on a series of drive bobbins moving freely in drive slots. This movement can create wear during service and promote noise. The slots can fill up with road & brake debris causing them to seize. AP Racings strap couplings can't suffer from any of these drawbacks. Therefore service life, brake noise and also brake pedal travel are all improved.

    A few other M3s running AP brakes

    M3 GT4
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    BMW Rahal Letterman Racing Team
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    The follow kit is to be covered on our installation:

    AP Racing - AP7100 6-piston Front Big Brake Kit for e9x M3 - 368mm with red calipers
    AP Racing - AP7150 4-piston Rear Big Brake Kit for e9x M3 - 356mm with red calipers


    AP7100/7150 Specs (taken from our website)
    - Fits behind OE 18” & 19” wheels
    - Compatible with OE ABS, Traction Control and Stability systems and factory master cylinder.
    - High-strength, lightweight, pressure-cast aluminum alloy body
    - 2-piece design for maximum rigidity in a streetable caliper
    - Fixed radial mount for best pedal feel
    - 6 sequential pistons to minimize pad taper and maximize pad area
    - Anti-knock back features for a consistent, firm pedal
    - Dust seals for everyday driving
    - Available in red or black

    AP Racing Discs
    - Directional curved vanes for maximum cooling
    - 2-piece modular design with aluminum alloy hat to handle the heat
    - Cross-drilled AND slotted for aggressive pad bite and additional cooling
    - Slotted-only optional for heavy track use

    Brake Pads
    - Now featuring the ultimate in high-performance street and track day use
    - Virtually fade-free Mintex Xtreme Motorsport Pad Compound
    - Consistent coefficient of friction cold to over 1300F
    - Linear response and quick release
    - Easier on discs than many current “high-performance” compounds
    - Lowest noise
    - Competition compounds also available

    2-piece disc assembly
    - Aluminum hat for reduced weight and better thermal conductivity
    - Fixed bobbin or full-float mounting
    - Curved vane venting for maximum internal cooling
    - Cross-drilled and slotted for best street performance
    - Slotted-only available for heavy track day use
    - 1- piece rotor option available in select kits

  4. #29
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    After contact with Brake Pros (AP Racing USA), we were able to schedule our M3 in for test fitment as the caliper brackets were not completed yet with final measurements needed to be taken and custom machined.

    A couple of weeks later, our new brakes arrived:

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    Let's begin:

    Front Caliper Fitment
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    Rear caliper fitment
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    Brake Pad sensor modification

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  5. #30
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    OEM vs AP BBK weights

    Stock Front Rotor - 22.6lbs
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    Stock Rear Rotor - 20lb
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    Stock Front Caliper - 14.5lb
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    Stock Rear Caliper - 11.25lb
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    AP7100 Front Rotor - 22.15lbs
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    AP7150 Rear Rotor - 18.20lbs
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    AP7100 Front Caliper - 10.25lb
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    AP7150 Rear Caliper - 9.85lb
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    AP7100 Front Caliper Bracket - 1.80lb
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    AP7150 Front Caliper Bracket - 1.25lb
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    Results:

    Total Rotor/Caliper Weight (stock system) - 136.70lb
    Total Rotor/Caliper Weight (AP 7100/7150 AP BBK Brake System) - 127.0lb

    Total Weight Savings - 9.70lb

  6. #31
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    Completed AP Racing 7100/7150 BBK installation

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    AP Racing 7100R Front Brake Upgrade
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    AP Racing 7150R Rear Brake Upgrade
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    Side view:

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    New wheels/rubber to be installed next as it's getting close to track time.

  7. #32
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    Yokohama

    New shoes were installed for last weekend's SoCal Euro event as we were invited to participate in Yokohama's booth on display.

    Yokohama ADVAN AD08s:

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    Sticking max rubber underneath the fenders was on the agenda, we decided on the VMR CSL Ultra-Staggered fitment. With our new partnership with Yokohama tire, it was time for the new AD08 lineup to be tested out.

    Wheel specs:

    Front: 19x9.5" VMR CSL, Matte Black
    Rear: 19x10.0" VMR CSL, Matte Black

    Tire Specs:

    Front: 265/30-19 Yokohama ADVAN AD08
    Rear: 295/30-19 Yokohama ADVAN AD08

    Pictures at the event (thanks to sard for photos):

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    Money shot:
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    More to come.

  8. #33
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    Another quick shot before the new tires were installed:

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  9. #34
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    And another showing the rear concavity:

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  10. #35
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    Did a quick photoshoot for VMR today with the Matte Black V713s that will be coming out soon:

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    Wheels are V713s with 19x8.5 fronts and 19x9.5" rears wrapped in Yokohama ADVAN AD08 rubber (245/35-19 & 275/30-19).

    Wheels will be removed and up for sale soon on a separate thread.

    In the meantime, enjoy!

  11. #36
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    To compliment the matte carbon trim during a short amount of downtime in between scheduling, we had couple of other items wrapped:

    OEM BMW S65 Intake and steering wheel trim in 1x1 matte fibre:
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    OEM Steering Wheel Trim in 1x1 matte fibre:
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    OEM BMW S65 Intake in 1x1 matte fibre:
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    The intake is simply beautiful beyond words and would be the center of attention in any engine bay - but it will not be going on this build.

  12. #37
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    Click here to enlarge

    Here's a teaser of what's covered next in our journal.

  13. #38
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    VF S65 Supercharger Update

    While we've spent a considerable amount of time on braking, chassis, wheel/tire choices and aesthetics - most will wonder what are plans for engine performance?

    VF Engineering in Anaheim, CA agreed to come on board with their upcoming S65 Supercharger which has been in development since Dec 08 debuting at MFest 3 and shown at Bimmerfest 2009 on their Project Stealth Fighter:
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    source: www.terabass.com

    Our Project M3 was dropped off at VF's headquarters for installation. at this time, our SuperCharger kit is considered "proof of concept" and not the finished product as a entirely new cast intake manifold will be released later this fall, running alongside Project Stealth Fighter at various events.

    Boost is at a moderate 5.5lbs with 510whp, an approximate 150whp gain on California's 91 octane. Vehicle is still in a "test and tune" state, with figures changing as further tuning is implemented.

    Good thing we upgraded to the 295 AD08 in the rear, we'll be needing them. Below is a quick overview of installation, thanks to VF for the photos:

    Intercooler Mounting photos:
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    Heat exchanger plumbing:
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    Heat Exchanger pump:
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    Reservoir tank with twin blowoff valves:
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    Intake removed, showing harness extension (will be cleaned up on cast manifold replacement)
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  14. #39
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  15. #40
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    Some completed shots the kit before front bumper cover installation:
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  16. #41
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    Completed transparency shot, pretty cool how this turned out:

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    Build is coming together nicely, vehicle will be monitored for some real-world driving/datalogging then back off to GIAC for tuning.

  17. #42
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    Competition Performance Steering Wheel

    Here's an upcoming teaser of the new steering wheel that will be installed in the next couple of days. I've never been a fan of the 50/50 Alcantara/Leather design - so we tool of the BMW PSW wheel and have it cut/rewrapped to our specs.

    The stock BMW Performance Steering Wheel was stripped down to the wire frame and cut to offer the "flatbottom" seen on other euro models and offer additional leg clearance.

    Stock LCD display and shift lights are retained, with the mode buttons being a bit more pronounced, easier to find in a bit more focused situations. The wheel is confirmed to fit within grip while the leather (very soft blend I might add) is both comfortable and non-slippery while driving.

    Stitching was also switched from standard white to black.

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    Our Competition wheel was topped off with a 1x1 matte steering wheel trim to further compliment the interior.

    Installed pictures coming soon.

  18. #43
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    Updated interior shot with the new Steering Wheel:

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  19. #44
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    Media Coverage

    Laidback at Mfest was nice to suprise us with the promos for Mfest:

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  20. #45
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    European Car Feature - March 2010

    We're happy to announce that our project M3 and 135i are featured in a six page spread in the March 2010 edition of European Car Magazine.


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    This issue is currently in your mailbox or newsstands. Web version of the article (with additional pics) now up on the European Car website:

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    2008 EAS BMW M3 & 2008 EAS BMW 135i - Dark Duality
    http://www.europeancarweb.com/featur...35i/index.html

  21. #46
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    Ericsson Front Bumper

    It's been a while since we've had an update in the journal, as we're preparing for Mfest, as well as the unveiling of the VF Supercharger system.

    While our thoughts are the M3 exterior is pure awesomeness on its own merit - the Amuse/Ericsson team designed some pieces that just work great, keeping respect with the body lines on the side panels and making an already aggressive stance better. An added bonus was the deletion of the side reflectors.

    The official Mfest flier shows how plain the exterior really is - we need to change things up a bit and add a bit of attitude:

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    Since we installed the Ericsson trunk last year - we felt a 1-year anniversary present was due to round out the front:

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    The Ericsson piece fits the bill nicely giving a subtle hint of serious business underneath the hood. The wider/lower air intake will allow maximum airflow to the heat exchanger while setting itself apart from other M3s on the road.

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    Stock bumper ready for removal:

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    OEM front bumper removed - ready for it's new look:

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    Pre fitment, sneak shot of Macht Schnell Intake Charge Scoops:

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  22. #47
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    wooooooooooooow Click here to enlarge

    My jaw is on the floor. Gorgeous car and AWESOME journal of mods and documentation. Click here to enlarge

  23. #48
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    The level of documentation is second to none.

    Very glad to see it all, absolutely incredible build.

    I am definitely looking forward to the impressions with VF! Plenum looks much, much better black I think.

  24. #49
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    Very nice write up! Thanks for sharing. Any dyno's of the VF kit yet?

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    Click here to enlarge Originally Posted by Sticky Click here to enlarge
    The level of documentation is second to none.

    Very glad to see it all, absolutely incredible build.

    I am definitely looking forward to the impressions with VF! Plenum looks much, much better black I think.
    Click here to enlarge Originally Posted by MSpiredM3 Click here to enlarge
    Very nice write up! Thanks for sharing. Any dyno's of the VF kit yet?
    The Intake Plenum is temporary, the final version and power numbers will be unveiled at Mfest.

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