| Here she is as she arrived after her travels.
She is very dusty from her time spent sitting in storage during the course
of the defining stages of what is soon to be. |
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| Here she is getting her first bath in a very long time. As
the dust and dirt rolls off her one can hear her say “I am ready for the
next phase of this journey" |
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After numerous conversations
and much consideration the decision was finally made to pull the
heart out of the 540 and replace it with a “Full Fledged” E39 M5 motor and
not just any E39 M5 motor but rather one of our custom built “Red Head's”.
The motor will be fully blue printed and as a part of the block preparation
we will install custom Darten sleeves, Arrow rods, custom spec'd
CP pistons (ceramic faced with Teflon coated skirts) and custom selected
rings, Schrick cams, and a fully machined set of heads that will
be ported, flow matched, and 32 larger valves with matched springs
and retainers installed. The rotating assembly will be balanced and
then each of the bearings will be hand fit to insure the desired
clearances resulting in an extremely strong base for the supercharger
system that will also become a part of this gal. In addition to the
gal's heart she will receive a new M5 transmission, a full SuperSprint
dual exhaust (whereas the OEM 540 has a single exhaust at the rear)
including small metal bed cats, with the drive trains power delivery
will be managed through a UUC lightweight flywheel and multi puck
clutch system. Over the next several weeks many more details will
be defined which will include the ultimate gearing as well and the
wonderful personal interior touches planned for this gal. But for
now the project had to start somewhere so a complete running donor
motor was purchased and the process has begun.
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| Here is the donor heart as received complete with wiring
harness, alternator, A/C, etc. This was not just any donor motor but rather
a running motor that we were able drive and give a physical or sorts before
making the decision to make it a part of this project |
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| Here the process of disassembling the heart in underway.
For most you will never see the inside of an E39 M5 motor however for those
that have been inside one or will one day it is on one hand a mechanical
marvel and on the other an endless array of parts that once disassembled
and sorted will fill several boxes. |
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| Here the heads stand waiting to be boxed prior to traveling
to the machine shop however the block is already wrapped and tucked securely
within the padded box sitting behind the heads |
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| Now that the heart has been disassembled and the key pieces
have been made ready for the machine shop here are the pieces of the puzzle
that now need to be hand cleaned and inspected before tagging and bagging
in preparation of the re-assembly process several weeks down the road. |
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| Here is a box full of pieces that have been labeled as trash.
None of these pieces will ever find their way into one of our custom built “Red
Head's”. |
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Now after completing much
of the preparation work such as machine work for the “RedHead” and the many custom fabricated
pieces to be installed during this project the project is now well underway.
The phase presently underway is the assembling and installing of the custom “RedHead” motor
during which time the OEM motor is being removed to make way for her new
heart.
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| Here the gal has finally taken her place on the “Throne” as
the sign that significant forward movement is about to commence. |
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| Here the custom heads are ready to be installed. It was
during this process that complete porting and flow matching of the heads
was completed, all 32 OEM valves were replaced with oversized pieces, and
then cam specific springs and retainers were installed to control the movement
now dictated by the Schrick cams. |
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| Here is the custom low compression pistons are ready to
be installed. The tops have been ceramic coated for the purpose of adding
a thermal barrier and the skirts Teflon coated so assist in the slippery
movement and extremely low wear characteristics of this rotating assembly. |
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| Here the crank is ready to go. The journals were all micro
polished and balanced. Because of the much lighter rotating assembly a
significant amount of weight had to be removed from the crank as can be
evidenced by the hole in what once was a Mallory plug in one of the crank
throws |
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| Here the fully blue printed block with the custom fitted
Darten sleeves is ready for final assembly |
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| Here the numerous core pieces have been inspected and organized
as the final assembly of the “RedHead” commences. |
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| Here the nose of the gal is just about ready to come off. |
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| Here the core support and cooling cores have all been removed
exposing the gal's old heart. None of the existing system will be used
as a part of the supercharged “RedHead” soon to be installed. |
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| Here the OEM single exit exhaust is being removed as the
new SuperSprint exhaust system starting at the headers all the way back
will be installed once the necessary modification at the rear of the gal
are completed so as to accept the dual mufflers. |
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| Here the process of removing the OEM rear bumper is underway |
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| Here the OEM rear bumper has been removed and discarded
as the replacement will be an OEM M5 bumper to facilitate the dual mufflers |
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| Here the transmission removal is well underway. This transmission
is being replaced with a “near new” OEM M5 unit and will be connected to
the “RedHead” through a UUC lightweight flywheel and multi-puck clutch
pack assembly. |
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| Here the gals old heart out including the original ESS supercharger
system and ready to go to a “to be determined” new home |
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| Here the gal's old heart, transmission, and misc core pieces
have been loaded and are now on the way to their new destination. |
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Now the gal is ready to be cleaned and prepped
so as to receive her new heart aka “Redhead” further enhanced by the
custom D/A supercharger system as seen on numerous other M5's over
the past few years. Once this phase has been completed the transformation
from 540 into a thoroughbred supercharged BMW inundated with a wonderful
list of personal touches as defined by her owner.
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| Here the blueprinted block is now ready to have the crank
installed |
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| Here the crank has been installed and we are currently completing
the torque sequence |
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| Here the first custom piston is being installed |
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| Here all of the custom pistons have been installed and the
block is now ready for heads |
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| Here the custom heads have been installed and now the secondary
components are ready to be installed |
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| Here the gal's heart aka “RedHead” is just about ready to
be installed |
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| Here the “RedHead” is being made ready to install |
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| Here the heart aka “Redhead” of the gal in her new home |
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| Here the SuperSprint headers are being installed |
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| Here the M5 transmission is being installed after delays
that came as the result of parts we found to be needed during the conversion
process. IN addition to the transmission the SuperSprint headers are being
buttoned up as well |
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| Here the SuperSprint headers have been installed. Now we
need to connect a few of the OEM sensors and install the slave cylinder
as furnished by UUC to complete the light weight clutch and flywheel installation |
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During
the next week several items will be tended to with the goal being to
bring the gal's new heart aka “RedHead” to life late next week. Once
the preliminary run in has been completed then the installation of the
supercharger overlays will commence.
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Over the last couple weeks during the Holidays
the progress has been slow and yet progress has been made. Much of the
time spent of late has been twisting and tweaking the gal back into shape.
There were numerous twist and tweaks made during the course of previous
modifications that needed to be corrected before true forward movement
could be made. In addition to this several small issues have had to be
dealt with and hardware conversions made to make the engine bay of this
gal as would have been if an M5 from the onset. At this time we have much
of the twisting and tweaking completed as such we have been able to move
a bit closer to the day when the supercharger is put into place.
Here the supercharger oil drain provision is being integrated into the upper
portion of the OEM oil pan. The area was drilled, tapped and then the same fitting
as located in the Vortech supercharger was installed which is connected between
the oil pan and the supercharger with a piece of ½” ID hose.
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| Here the SuperSprint small metal bed cats and the SuperSprint “X” pipe
are being installed after a slight delayed that resulted from the need
for some M5 specific pieces that were required as a part of this conversion
process |
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| Finally we have SuperSprint dual exhaust all the way back
to the muffler section. All the remains with the front portion is the final
alignment of the system and then tighten everything into place. As the
project progresses the rear trunk/boot floor pan section will be replaced
with the OEM M5 floor section thus allowing for the proper fit and OEM
installation procedures |
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| Here are a few of the pieces removed from the OEM filter
lines and have be prepped for the integration stainless steel tubing and
the "AN" ends so that the XRP HS-79 can be tied in as a part
of the oil filter relocation process. |
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| Here is one of the many pieces that had to be modified during
the supercharger conversion process. This particular piece is located within
the oil pan and was originally a component of the OEM oil separator drain
back system however with the supercharger conversion a custom oil separator
and crank case breather system will be installed. |
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| Here the “RedHead” has been brought to life now breathing
and pumping fluids on her own. The mechanical and electrical transformation
from 540 to M5 has been successfully completed and as can be seen she has
a “clean bill of health” |
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| Here the OEM Radio and the MID control unit in preparation
of the new equipment slated to be installed into this location. In addition
the center vent unit was removed because of previous damage and will be
replaced as well. |
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Here is another of the numerous corrective processes
required during this gal's build. In her previous life a supercharger was
installed during which clearances were an issue as such they cut the ABS
motor/junction block bracket off and relocated it. Sadly the workmanship
was less than stellar as such the bracket is about to be removed and then
a donor OEM bracket will be located and installed back in it's original
location.
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| Here is the bracket as it was relocated in her previous
life. When installed by the factory it was a couple simple spot welds that
held it into place however someone decided to MIG the entire seam during
the relocation process as such this phase is a PITA |
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| Here is the underside of the bracket as it was left by the
person that previously relocated it. The braces were cut and left hanging,
raw edges, exposed, in short a rough job |
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| Here the bracket has been removed and now the area needs
to be dressed so as to be made ready for paint and the installation of
an unmodified OEM bracket |
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| Here the area has been prepped and is now ready for final
sanding, paint, and the installation of the donor OEM bracket |
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The owner of one of the extreme Supercharged M5's had to
come in from out of town to take a peak at this project. After what seemed
like (at least to me) forever as he walked around and around her we were
finally given the "Thumbs
Up" at which point Noah was finally able to relax and smile. |
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| Here you can see that we had to remove yet another OEM bracket
from the right side shock tower that had been relocated by another during
the previous Supercharging process. In addition we had to remove a couple
OEM 540 brackets from the driver side as this gal's conversion into an
M5 continues |
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| Here the oil filter housing which was temporarily secured
into place during the initial firing of the engine and the DCS compressor
pump have been removed. The oil filter housing will soon be remounted on
the passenger side once the new ABS brackets have been installed back into
their OEM locations. The DSC compressor pump will be relocated under the
driver side frame. In order for this to take place both of the OEM M5 DSC
compressor pump brakes line were acquired and now will be slightly modified.
FYI; the OEM placement for the DSC compressor pump is on the outside of
the driver side frame rail however because of the supercharger's intake
system it must reside directly under the frame rail for adequate clearances. |
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| Here the OEM oil filter housing, the DSC compressor pump,
and the OEM 540 DSC compressor pump lines reside. Both the oil filer housing
and the DSC compressor pump will be relocated however the OEM 540 lines
will be retired from service as the migration of M5 pieces on to her continues |
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| Here the OEM wood grained interior trim has been removed
and is soon to be replaced with Black carbon fiber interior trim to match
the evolving personality of this gal as well as the many personal styling “Qs” incorporated
into this project . The black carbon fiber interior trim will find company
within this gal along side such items as the new front seats that have
fully exposed backs finished in black carbon fiber too |
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| Here one of the many custom fabrication processes is underway.
In this case the final stage of the custom oil transfer bungs are being
completed |
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| Here is one of the custom bungs used for the oil filter
relocation process now ready to be installed as part of the oil filter
relocation process |
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| We are asked all the time what it takes to complete the
supercharger conversion process which is a very difficult answer to share
because in order to mechanically supercharge a car when compared to integrating
systems in such a way so that they appears to be as OEM are two completely
different approaches. We only integrate systems when compared to adding
them on top of the existing as such h ere are a few of the
custom designed and fabricated pieces and associated hardware required “only” to
successfully complete the oil filter and power steering reservoir relocation
process. In addition to this phase of the supercharger integration process
there are many more that require a similar level of custom design and fabrication
work. In this case we have pieces being completed for the two gals presently
under the proverbial knife . |
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| In the pictures you can see that we use XRP's HS-79 line
for the oil transfer process. This is an example of how we approach the
conversion process because the HS-79 hose is many times more expensive
when compared to other available options such as typical stainless steel
braided hose. However the HS-79 is the lightest, the most flexibly which
equals an increased serviced life, and has the highest flow rating per
a given size because the inner diameter of the hose (when compared to a
given size such as #10, #12, etc.) is the largest in the industry. |
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| Since this gal began her life as a 540 the OEM location
for the DSC compressor (as can be seen in the first picture) was initially
on top of the driver side (USA) frame rail. In the case of the OEM M5 the
DSC compressor is located on the out side of the driver side frame rail
(USA) . In both incidences the final placements needs to be below and just
inside of the driver side frame rail so as to accommodate the custom air
intake system for these supercharger conversions. Here you can see that
the relocation process is underway |
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| Here the custom DSC compressor bracket is now ready for
installation |
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| Here the DSC compressor has been mounted into place however
it will remain loose until the OEM M5 brake lines arrive from Germany so
we can complete this phase of the 540 to M5 to supercharged M5 conversion
process. |
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| Here the OEM ABS pump support brackets are being Tig welded
into place. Earlier in this project we shared that another facility had
bent cut, twisted, and then relocated the OEM brackets in a rather disheveled
manner as such they were all removed so that pristine OEM brackets paced
back in their proper OEM location could be installed. |
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| Here the OEM brackets have been successfully installed and
the ABS pump set into place for final fit. Now the ABS pump will be removed
so the area can be properly prepped and painted before the final installation. |
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| Here we have removed the OEM A/C dryer bracket because during
work done at another facility it was poorly modified. In addition it was
no longer properly secured into place and furthermore the disheveled looking
raw edges were never dressed or painted |
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| Here is the OEM secondary air pump bracket that is supposed
to secure to the underside of the AC dryer bracket. Sadly as can be seen
in this picture it too was poorly modified and then when the secondary
air pump was installed only 1 of the 3 mounting points was used as such
the secondary air pump simply swung around akin to a monkey on a vine. |
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| Here is the new OEM AC dryer bracket ready to be installed
as well as a picture allowing the comparison of both. It is truly very
sad because in a case such as this the owner of the gal likely would never
have known what was done previously because it is not a visible location. |
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| Here the new OEM AC dryer bracket and secondary air pump
bracket is being properly installed with “no” modifications |
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| Here the area that had the new OEM ABS brackets located
back in their original location are being prepped for paint |
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| Here the brackets and the surrounding area has been painted
to an OEM color and texture. |
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| Here the ABS pump assembly is being reinstalled for the
final time |
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| Here the ABS pump assembly has been secured into place and
all of the wiring was returned back as would have been on an OEM E39 M5.
In addition power steering reservoir has been relocated; in this case we
use one that is from a BMW Z8; it appears as an OEM E39 M5 reservoir however
the nipples are angled differently. The original location for the power
steering reservoir was located on the driver side (USA) |
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| Here is an example of the numerous custom pieces used throughout
the supercharger conversion process. These custom cut gaskets rest on the
top of the OEM throttle bodies and are sandwiched in-between the throttle
bodies and the custom billet aluminum CNC'd intake manifold plates |
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| Here are the custom billet aluminum CNC'd intake manifold
plates as they are being installed on the "Redhead". These fully machined
plates have been machined for o-ring sealing in-between the manifold plates
and the lower plenum so as to insure proper sealing and also allow for
ease of maintenance. In addition all of the threads have steel inserts
so as to insure a long trouble free service life |
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| Here the custom anodized CNC'd billet aluminum supercharger
bracket has been fit for the first time along with the Vortech supercharger.
Here is what some refer to as “Proof of Life” |
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| Here is the complete Ground Control system after being inspected
and made ready for installation |
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| Here the rear suspension is being tackled; at this phase
the interior is being removed to garner access to the upper shock mount
points |
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| Here the rear Ground Control suspension has been installed |
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| Here the installation of the front suspension is well underway |
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| Here the front Ground Control system has been installed |
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All the ride height settings have been preliminarily
made however once the gal has sat on the springs for a bit the final adjustments
will be made and then the gal will be aligned before being deemed road
worthy.
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| Here are the various OEM E39 M5 DSC compressor lines as
received from Germany. Now they need to be custom bent to work with the
relocated DCS compressor |
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| Here the OEM M5 DSC compressor lines have been installed
and the DSC pump is firmly in place for the remainder of the project |
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| Here is the custom oil separator ready to be installed on
the gal |
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| Here the custom oil separator has been installed as it will
remain throughout the remainder of the project. All it needs is to be freed
of the extra thread sealant and it is ready to be plumbed. It was during
this process that a mock-up supercharger belt is set in place to verify
that we have adequate clearances. As the numerous secondary systems associated
with the supercharger conversion process are installed clearances become
a bit snug. |
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| Here the process of installing the XRP HS-79 oil transfer
lines is underway. This is one of the many steps required during the oil
filter housing relocation process. |
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| Here you can see the blue XRP lines being dry fit as the
means to verify the placement of the stainless bracket used to secure them |
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| Here the custom lower oil filter housing mount ready to
be installed |
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| Here the installing of the upper and lower oil filter brackets
is underway |
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| Here the oil filter housing is being dry fit as the means
to confirm all fit associated issues prior to final installation and plumbing |
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| Here the oil filter housing and the custom brackets have
been mounted for the final time and the XRP HS-79 lines have been fit.
The next thing is to have the ends crimped on the lines and then the power
steering reservoir can be installed and plumbed |
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Here the XRP HS-79 oil transfer hoses along
with the power steering reservoir and blue XRP hoses have been installed.
At this point the oil transfer hoses have been fit into place and installed
at both the custom bungs on the gals heart as well as the custom bungs
located on the relocated OEM oil filter housing for the last time. However
two pieces of the puzzle remain missing; there are two stainless steel
securing plates being fabricated that will complete the hose securing assembly
located at the leading edge of the oil pan at which time the 2 temporary
zip ties holding everything into place will be removed. It will be at that
time that the XRP stainless steel braided Teflon inserted #4 hose will
be installed. This will be used to feed the supercharger with oil. In addition
to these items the larger of the two power steering hoses has been secured
into place at the power steering reservoir for the last time and also secured
to the nipple at the rear of the power steering pump. The smaller of the
two hoses will be secured under the oil pan once the stainless steel brackets
have been completed however since it is ultimately routed and then connected
to the power steering oil cooler on the driver side (USA) next to the radiator
this connection can not be completed until the core support is back in
place.
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| Here the back of the gal has been completely disassembled
in preparation of the removal of the OEM 540 trunk floor pan and in its
place a new OEM M5 trunk floor pan will be installed. The purpose for this
is to properly complete the gal's transformation from 540 into a M5 and
in the case of this phase so that the OEM mounting points will be in place
for the Super Sprint dual exhaust as well as the proper battery placement
at the center rear of the gal |
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| Here the engine bay was sealed up and made ready for her
visit into the body shop. Several of the previously set into place pieces
have been removed as a preemptive measure against damage which can be caused
as the result of dust with in a body shop environment. Once she returns
from the body shop the supercharger will be reinstalled for the last time
and the installation of the various secondary systems will once again commence. |
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| Here the gal is at the body shop undergoing surgery within
her boot area. During this phase the OEM 540 floor section is being removed
so that the OEM M5 floor can be installed |
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| Here is a component of the OEM M5 floor pan section prepared
and ready to be installed once the remaining OEM 540 floor section has
been completely removed and the area made ready for the new floor section |
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| Here the process of the removing the OEM 540 floor section
removal is well under way |
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Here the OEM M5 trunk/boot floor has been
installed. Now we will be able to install the pair of SuperSprint mufflers
as designed for an M5. The large opening in the center of the floor pan
is where the OEM M5 plastic tub will be installed which will house the
M-Mobility kit and the soon to be relocated battery. Certainly this process
was more involved when compared to simply twisting and tweaking the OEM
540 floor pan section so as to accommodate the fitting of dual mufflers
into the OEM M5 location however completing it in this manner retains
the structural and cosmetic integrity of the gal.
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Here the interior of the trunk is in the final
stage of the 540 to M5 conversion. During this phase interior trim pieces
are being installed; in addition the original 540 positive battery cable
that runs from the trunk through the cabin and under the passenger seat
is being replaced with an OEM M5 cable because the battery is now fitted
as an OEM M5.
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| Here the “All” black carbon fiber GTR style hood created
by Vorsteiner is being made ready for installation. The pictures do not
do the looks justice as up close and personal it is truly a stunning piece
of art work. |
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| Here the Redhead is having the supercharger and associated
system installed for the last time |
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| Here the full carbon fiber GTR style hood has been installed.
Not only does it look stunning but it fits as well if not better than OEM.
We were directed by another to use E46 M3 hood strut rather than OEM E39
hood strut because the OEM E39 hood struts are designed for a much heavier
hood. As the result of using the E46 M3 hood struts the hood opens as closes
smooth as silk |
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| Here is one of the many cool little CNC machined pieces
that bring this project together. This particular piece allows the OEM
oil pressure sender and the supercharger's oil feed line to share the same
OEM oil discharge port |
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| Here the final assembly of the lower plenum is underway.
It is during this process that the custom CNC billet intake manifold plates,
the custom CNC machined velocity stacks, the custom CNC machined intercooler
water transfer blocks and the custom intercooler are installed. We use
a combination of custom throttle body gaskets and compliment of seal o-rings
throughout this process insuring that the boost created is forced down
her 8 individual throats aka throttle bodies. |
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| Here the installation of the right side OEM M5 muffler bracket
is under way. It is been fit into position and now needs to have the final
welding completed |
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| Here the installation of the left side OEM M5 muffler bracket
installation is underway. Unlike the right side the left side requires
a placement notch be cut and finished prior to the final fit and welding
of the bracket. |
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| Here the OEM M5 muffler shields are set into position verifying
that everything fits as OEM prior to the welding of the brackets which
is the final mechanical stage of this process and then the areas will be
painted. Once this is completed the high flow SuperSprint mufflers will
be hung in place which will complete the full SuperSprint exhaust installation
as well as complete the transformation from single 540 exhaust into an
true OEM M5 system. |
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| Here is the new OEM M5 radiator soon be installed in the
gal. The 540 radiator removed has a much smaller core size as such the
Redhead would never have been happy during the heat of the summer |
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| Here is the new OEM M5 core support along side the original
core support. We are replacing the core support because folks that worked
on her in the past elected to cut off key pieces and also welded some rather
ugly looking brackets |
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| Here the final piece of the SuperSprint exhaust is being
installed. The gal now breaths through a complete as designed M5 exhaust
from the headers all the way through the SuperSprint high flow race mufflers |
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| Here the final assembly of the gal's heart is well underway.
The final plumbing is being installed with fluids soon to follow |
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| Here the various fluids are being installed as we will bringing
her back to life once again very soon |
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Now over the next 2 weeks the custom sound and
navigation system will be installed which is one of the significant personal
touches being completed on the gal.
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| Here the new custom black carbon fiber rear bumper diffuser
based on the OEM insert has been completed and is now ready to be installed
when the gal is ready for the installation of the final exterior pieces |
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| Here IMO is a good sign of things to come; Ash, one of the
fellows that I work very closely with when it comers to custom cabinet
and stereo work is about as detail oriented as one can be. This is what
a typical drawer of his tool chest looks like |
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| Here the rear package tray has been opened up and modified
so as to allow the proper porting required for the soon to be install JL
Audio subwoofers. The OEM rear speaker were removed and replaced as well
with JL Audio's finest. In the case of the new speakers they are separates
as such a second harness had to be run on which a OEM speaker connector
was used so as to insure the easy of future within this area |
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| Here the numerous signal and video wires are being installed
along the left side of the car. The reason that the left side is chosen
is because the OEM power wires run along the right side so placing everything
along the left side will control any potential electrical interference
caused from cross bleed when wires are run along side of each other. The
wires will be feeding and receiving signals from and for the amps, speakers,
rear camera, and the cross over system |
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| Here the custom subwoofer enclosure is under construction.
Take note of how thick the plexi-glass is. This was needed so as to insure
no panel deflection during those moments that the subwoofers are pumping
hard. |
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| Here the JL Audio 500 watt single channel that has been
allocated solely for the subwoofers can be seen as final measurements were
taken. There is a much larger 4 channel JL Audio amp allocated for the
primary speak system. |
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| Here Pioneer's latest Z2 stereo/navigation unit has been
set into place. As can be quickly seen; there is much to be done to have
the finished look appear as OEM and in addition to the Pioneer unit there
will be two AutoMeter gauges occupying the same area. The dash trim and
the surrounding trim for the Pioneer are all being completed in black carbon
fiber |
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| Here is an example of some of the wiring being used to successfully
integrate the primary and secondary systems into this gal. One such secondary
component is the XM Traffic module that can be seen. |
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| Here the OEM interior trim pieces are being made ready to
install after having them all treated to an awesome black carbon fiber
treatment |
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Here the latest JL Audio components are being
installed in a methodical and very detail oriented manner. During this
process the careful integration of the new systems with the existing space
and OEM harnesses was carefully considered so that in the end there will
reside an awesome sounding and looking system and at the same time maintain
the OEM look as well as access to the numerous compartments located throughout
the boot area. You will see that the primary 500 watt JL Audio amp is located
behind the rear seat and fully trimmed in such a manner that when the seat
is lowered it presents itself as wonderful eye candy and then the solo
JL Audio sub amp was incorporated into the base of the subwoofer enclosure.
Both amps were mounted and the surrounding trim was designed in such a
way to insure proper air circulation during even the most extreme of music
events.
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| Here is Pioneer's latest offering; their AVIC Z2 after being
carefully integrated into the OEM has now been secured in such a way as
to allow for future service and to install that the unit remains stable.
I should share at this point that this installation is not for the meek
of heart. If an OEM style installation is the goal because the unit is
large and required extreme work in order to successfully complete this
process. |
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| Here the truly custom black carbon fiber closure/face plate
is being fit into place. Within the panel will be a pair of Auto Meter
gauges and the surrounding trim will also be black carbon fiber so the
tie in and look in phenomenal. In addition to how the custom closure/faceplate
looks it was designed to remain extremely easy to remove with no concern
for damage for future service in a manner similar to what may have been
offered as OEM |
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Here the back seat area is being opened to show the awesome
systems primary JL amp installed. The picture show that the access is
very user friendly and serviceable and then once the finish trim has
been removed you can see the extreme attention detail maintained throughout |
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| Here the boot area that was converted by us earlier to M5
specifications remains fully functional. You can see that the care a detail
resides whether an exposed area or a place that most will never visit.
The driver side rear now holds all the cross-over and is the place for
the majority of the wiring and then in the right rear compartment is the
battery junction block mounted on a very nice finish panel. |
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| Here the standalone JL subwoofer amp and the pair of JL subwoofers
have been fully installed and all of the finish work has been completed |
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Now to say the system looks awesome would not
even come close to how the system sounds as played through the Pioneer
head unit supported by all of the JL audio components; phenomenal is
the word that has been expressed by many. The system is feature packed
with DVD, Bluetooth, Ipod interface, XM radio with traffic, backup camera,
and navigation
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Here the custom carbon fiber intake tube is be cured under
the heat lamp. During this process we are bonding a custom machined securing
collar to the carbon fiber using a special mix of Hysol |
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| Here the upper/ primary electric fan bracket is being fabricated
so that once the gal returns from the painter this as well as the few remaining
overlay systems can be installed thus making the gal to be exercised |
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| Here the electric fan is being temporarily fit on another
radiator so as to confirm that everything fits perfectly. The fan will
be mounted using all stainless steel fasteners and the custom aluminum
brackets. On the lower bracket is integrated a OEM BMW rubber isolator
to eliminate transient vibrations and harmonics thus increasing the service
life of the unit. |
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| Here the final assembly sits ready to be installed. |
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Here are the new IForge wheels soon to be fitted with
Pirelli tires so that the gal has some new shoes to be exercised on |
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Now there is no doubt in the minds of all that
are aware of this gal's transformation that the project and the process
has been extreme nevertheless as can bee seen in the following pictures;
she is now visiting the body shop and the process she is presently
under going will forever set her apart from the pack. She will be stealthy,
wicked, BADASS, and to some they will think that BMW AG may have actually
offered her as a limited edition but in the end she will be the only “ONE”
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| You will also notice the extreme care taken to protect all
of the black carbon fiber surfaces that we just completed as part of this
project by covering everything with painters tape. This care and attention
to detail is just one of the many things that set our projects a part from
the crowd. |
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| Here the new OEM bumper is being fit for the custom powder
coated intercooler grill. Once this is completed then the bumper will be
placed in the hands of the painter as the exterior detailing and styling
changes continue to move forward |
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Here the custom powder coated grill has been temporarily
installed so as to confirm that everything is perfect prior to final
preparation and paint
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Even though the gal remains in the hands of
the body shop as she continues to be massaged other phases of the project
continue to move forward. Here are the Misano's stunning Cobra seats
as received from Italy . These were created using a wonderful mix of
OEM style leather and Alcantera insets. In addition we had them completed
using black thread for the Cobra logo and the perimeter deviated stitching.
This was done for contrast and also to tie them in with the wonderful
custom black carbon fiber accents now methodically placed throughout
the interior of the gal. The primary structural portion of the seats
were created from black carbon fiber and then the hardware is a nice
mix of billet aluminum pieces and stainless steel. The process of acquiring
these seats has been long (7 months) and at times frustrating as the
first set that we received had white stitching as such they had to be
returned only to have the arduous process repeated.
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During the gal's stay with the John at the body shop she is being made
ready for a new coat of paint as well as some very cool exterior modifications.
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Here the rear quarter panels have been stretched and then
material added as we make room for the huge custom I-Forge wheels wrapped
in 325 tires. During this process we retained the folded OEM exterior
wheel opening lip and then had widened the rear bumper so that when completed
one will sense that she could have come from Germany this way |
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Well; it has been a long time since we last
updated this particular project. Not because nothing was happening but
rather because over the past many months there have been numerous ideas
considered as well as some trial and error massaging as such we elected
to refrain from updating until we had a firm handle on the final direction
that this gal was heading. Now certainly her heart and the fundamentals
have always been know however in the end this gal's Poppa wanted her to
be something very special.
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| Here she is having her hind quarters massaged. We decided
that we wanted to give her a muscle car back end complete with huge wheels
and tires however once completed we wanted her to appear as if she could
have been presented this way from day one; an OEM feel as if truly a Motorsport
exclusive. In completing the massaging of her hind quarters we also massaged
her rear bumper so that once in place it will appear as if OEM rather than
simply using some sort of add on wings or ?? that others have used to blend
the rear bumper into a wider rear stance. |
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It was decided that she needed a truly custom rear spoiler
to compliment the rest of the project as such we began with a clean slate.
It was also to be black carbon fiber to tie in with a few other subtle
detail items being integrated as well.
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| Here is what we began with; a simple fiberglass release
as taken off another E39. |
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| Here we are massaging away attempting to create the perfect
spoiler for this gal. Bondo on …… Bondo off…. and the cycle was repeated
over and over again as we completed one idea after another until finally |
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| After creating numerous cool looking spoilers we found our
self and the gal's owner creating what ended up looking very similar to
the CSL spoiler as offered in Europe for the E46 M3. This was really not
a huge surprise to any of us when you consider that the gal's back side
(albeit larger) also resembles a E46 M3. In doing this we created a completed
piece that in our opinion could have easily been presented by the team
at BMW in Germany. At this point the handmade plug has been tendered to
the composite team to convert it into a working mold so that from
which can come a stunning black carbon fiber piece. |
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| Here the painting of the gal is well underway. She is being
massaged from stem to stern with her color being transformed from OEM straight
black to “Carbon Black”; a color offered by BMW as an option. Carbon black
is a color that dances in the lights and accentuates her every line. During
this process she was fully disassembled so that all of the jams could be
tended to during this color transformation process and the individual pieces
tended to one at a time. |
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Here she has been painted and painstakingly color sanded
and bluffed. During the painting process her custom IForge wheels were
also treated to a custom color match within each of the spokes. Now we
await a few trim pieces to be installed and then she will begin the final
phase of her journey |
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Please click HERE to
view and read about the Final Phase
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