Well; finally after many months she returns to us appearing
as a completely difference gal. During her time away she received
far more than a paint job but rather a complete new look. She
had her rear end widened so as to accommodate the huge wheels
and tires as well and numerous other very cool personal touch
items. Once of the most time consuming items tended to while
she was away was the creating of the carbon fiber rear spoiler
that was unique to this gal. The gal's owner worked relentlessly
with us as the process which at times was extremely frustrating
unfolded until finally his dream became a reality.
Now that she is back the process of completing the integrating
of the numerous supercharger systems as well and the final
list of personal touch items will be tended to however before
we do anything we will be wrapping much of her in clear plastic
with our focus being on the anticipated high risk areas before
we begin to massage her again.
Here you can see the level of detail and concern provided
during the plastic film installation process. There were no pre-cut pieces
used but rather this process is in the truest sense custom and unique to
this gal. The bonnet was not wrapped in these pictures because we want
it to be a full seamless pieces as such have to wait for additional 54” material
to arrive. We found the rolls that we had on hand had blemishes as such
had to be returned to the manufacturer.
Here is the gal's heart ready to have the secondary systems
integrated and brought on line. Even without the bonnet being wrapped we
are able to being the process of massaging her again however the first
things that we did was remove her front bumper so as to insure that no
damage is caused to it during this process.
Now we will be integrating the intercooler system's circulation pump,
the AquaMist water injection system, new HID lower driving lights,
a pair of the clear lens high intensity headlamps, and a discretely
integrated front and rear radar system.
During this time we will also be tending to a couple final touches
that need to be tended to within her interior. We need to integrate
the custom leather and top stitched Cobra seats as well as a custom
perforated leather and carbon fiber steering wheel designed to integrated
with the custom carbon fiber trim and stereo/NAV system that we integrated
earlier in this project.
It took us several attempts however
we finally received nice quality 58” material so we could wrap the gal's
bonnet
Here the process of wrapping her bonnet with plastic film
is underway
Now we will be tending to another
personal touch item. In this case we will be “integrating” a radar and
laser detection system within this gal. The goal (even though she will
be noticed) is for her owner to know in advance who is looking at her
whenever possible. Now not being a fan of most radar and laser systems
because of the lack of OEM integration we go to great lengths to address
this concern.
In order to integrate the radar/laser system we needed to
get back into the gal's wiring heart. Because of this we will also be integrating
the TV tuner as well as completing at least one more personal touch item
to her new instrument cluster. The radar/laser control panel has been placed
where it is easy to use and see as a component of the cockpit environment
and yet equally easy to make all but disappear at will.
Well after several discussions regarding the final personal touch
items that this gal is receive a road map has been created as such
the final phase of this project is underway. We will be completing
some of the known wiring and integrations issues that resulted when
we converted her from a E39 540 into a 39 M5 and at the same time introducing
a few more E39 M5 specific items such as the instrument cluster. Now
even this process created a bit of a challenge because it required
the instrument cluster from an E39 M5 the lens cover from an E39 540
and the customer furnished carbon fiber face that now ties in beautifully
with the custom black carbon fiber trim and the custom black carbon
fiber and black leather steering wheel. It is also time to integrate
the custom upholstered Cobra Misano seats
Here is a portion of the uniquely machined strut bar that
was then powder coated red to match the gal's valve covers aka “The Redhead”.
We wanted a subtle yet significant difference so that it would be seen
and yet be the focal point within a stunning engine bay
Here Ash is very carefully integrating the black carbon
fiber instrument cluster face and the associated trim rings prior to the
instrument cluster being integrated into the gal
Here Noe is methodically tending to several of the final
electrical conversion issues as well as upgraded the new clear Hella headlights
that will adorn her nose.
Here a myriad of dash related items are being tended to.
The custom E39 M5 instrument cluster is being installed, the Pioneer Z2
audio system is being updated and converted to fully time video operation,
the secondary systems such as TV and iPod are being brought on line, and
an OEM E39 M5 interior rear view mirror was installed.
Here are the fruits of the labor and the view as will now
be enjoyed by the driver.
Here the process of integrating the custom upholstered
Cobra Misano seats is underway.
We continue to complete many of the personal touch items; in this
case we have integrated the carbon fiber lower from spoiler and the
custom powder coated mesh grill.
As a finishing touch we are incorporating a pair of machined aluminum
struts between the leading edge of the carbon fiber spoiler and the upper/inner
portion of the opening in the bumper.
Here we have integrated the carbon fiber front spoiler and
the custom powder coated mesh grill. All that remains here is the integrating
of the machined aluminum struts.
We continue to methodically reassemble the gal for the final time.
With all of dry fitting having been completed this phase is when all
of the details appear.
Here we have a special blend of Hysol being prepared for
the bonding of the custom machined aluminum bungs into the custom carbon
fiber intake and discharge tubes.
Here we have methodically integrated the custom machined
aluminum bungs for the supercharger by-pass system as well as the AquaMist
water injection nozzles into the custom carbon fiber intake and discharge
tubes.
Here we have installed the custom carbon fiber intake and
discharge tubes for the final time as such all of the secondary plumbing
and hardware is being reintroduced at the same time.
Here the custom intake system has been integrated.
Here we have integrated the AquaMist water injection pump
onto the bumper reinforcement. This is an ideal location as it receives
good air flow and remains accessible for service should the need arise.
Here we have installed the bumper reinforcement as well
as the custom heat exchanger for the last time as we continue to make this
gal ready to be exercised.
As we continue through the final assembly process occasionally we still
find a detail item worthy of integrating. In this case we decided to
change the OEM tan carpet to OEM black and at the same time change the
lower transition trim pieces at the door sills, the B pillars, and the
foot well areas. This also included the very nice m5 specific dead-man
pedal
Here we are removing the old carpet so as to make her ready
for the new OEM black carpets.
Here we have fully integrated the new OEM black carpets
and OEM black trim along with the custom front and rear floor mats.
Here are completing the assembly of the front bumper which
includes the custom aluminum struts.
Here we are integrating a pair of scuff plates to protect
the high risk area of the carbon fiber lower spoiler.
Here we are integrating the AquaMist water injection draw
line from the OEM washer reservoir to the AquaMist pump neatly mounted
within the front bumper reinforcement.
Here the 3 secondary relays have been integrated thus bring
the water injection, intercooler pump, and the primary electric fan on
line.
Here the final pieces of the custom radar and laser detection
system have been integrated.
Here the custom steering wheel has been fully integrated.
Here the nose of the gal is being installed for the final
time as we continue with the final assembly process.
Here a the OEM washer nozzle wiring and hoses have been
modified and neatly routed and secured under the carbon fiber bonnet.
Here the custom Cobra seats are being fit.
Over the next several days we will be putting the final pieces of the
puzzle into position as we make this gal ready to head home
Here the work within the DME compartment has been completed;
all secondary systems have been integrated and the proper operational status
of the systems confirmed.
Here we integrated a black leather center console armrest
into the gal to complete the contrasting interior layout. This was a last
minute request as such we had previously used the area under the armrest
for secondary electronics so we were not able to use the factory cubby
style setup as such we modified the existing armrest slider to accept the
new black leather armrest.
Here the ///M 5 badge has been installed on her boot-lid.
Here the area within the driver side wheel well has been
completed and is now ready to be sealed with the inner fender liner and
lower body panel.
Here the oil filter drain line is being integrated; we do
this because we relocate the oil filter housing from the driver to passenger
side (USA version gals) during the integration of the supercharger system
which then eliminates the ability for the oil filter housing to drain back
into the pan as such an easy to access bulkhead fitting is integrated.
Here the gal's engine bay has been completed; all fluids
installed and she has been once again brought to life.
With the engine bay integration completed her placard is
finally put in place.
Here she is being made ready for the last detail items before
she begins her journey home.
We are continuing to tend to all of the final detail and personal touch
items as this gal is only days away from going home.
Here Branson is methodically removing all of the old window
tint so as to make her ready for not only fresh tint but also darker
tint. We decided to use limo tint through the rear of her and medium
tint on the two front doors so as to insure reasonable visibility for
the pilot
During the integrating of the Cobra Misano seats we found that the OEM
steering column functions quit working. After much research we found
that we needed to integrate an OEM body control module so that the proper
signals could be generated. We decided to locate the body control module
under the carpet just in front of the driver seat. This is a safe out
of the way place and yet remains accessible for service over time.
Here we removed a small section of the hard Styrofoam located
within the floor cavity and then fit a piece of extremely soft high density
foam for the module to both rest on and be wrapped in prior to the carpet
being put back into position.
Here we had to create a custom wiring harness for the body
control module as well as the seat belt notification system. Once completed
using OEM connectors the entire assembly was integrated making her now
ready to receive her driver seat for the last time.
Now we will be completing the integrating of the Cobra Misano seats;
this has been a very challenging phase of the project for many reason
some of which are the fact that the seat design is such that extremely
careful placement is required so as to insure the fore and aft movement
with no interference. This is because the sport seats are much broader
at the shoulders and at the thigh bolsters. Then add to this integrating
the OEM seat belts; particularly the OEM Nitrogen charged latch side
would prove to be difficult because once again the amount of available
free space is slim and none.
In any case; thanks to Tony and his ambitious team within VAC Motorsport
a set of universal floor mount adapters were received that allowed us
to manipulate the seat placement until everything worked and fit perfectly.
Once this phase, the dry fitting/mocking up was completed Brian; a member
of the VAC Motorsport team worked relentlessly to create the custom floor
mount adapters in record time. He created a set of custom CNC machined
billet aluminum floor adapters just for this gal. Now the mounting of
the outer seat belt was relatively easy however as projected the inner
seat belt latch mount provided both VAC Motorsports and our team several
challenges. Finally with Greg and Mark initially working within the Solid
Works program and then throughout the machine shop success was realized.
In our opinion the combined aka team effort produced far more than simply
stellar results but even more so the team effort created exactly what
this phase required.
Here are a few of the steps as we complete the integration
of the Cobra Misano seats for the last time.
Here the Cobra Misano seats have been fully integrated.
Now we will tend to the final detail items as well as the final detailing
as this gal is heading home in a few short days.
Now we are going to install a custom D/A windshield visor banner as
one of the final personal touch items requested after which she will
run through her paces one last time before she is made ready to go home.
During the final stage we will verify that all primary and secondary
systems are on line and operating properly and then the last thing that
we so is hook her back up to the GT1 and let BMW tell us that she is
truly happy.
Here the windshield banner is being fit into position.
Here she has just completed her physical and she passed
with flying colors; she is running, at normal operating temperature, and
happy as evidenced by these pictures.
Here is a short video of her as she remains running; there is no doubt
that she is ready to go play and that her owner is anxiously awaiting
her arrival home.
Here the process of installing the windshield banner is being completed.
During the process of installing the banner Evan elected to make a change
as such a new banner was created and installed before all were happy
with results. The banner was made a bit darker gray and the layout of
the banner was also altered.
Now that the project as defined has been completed we will now complete
the final detailing as she will be loaded with the transporter in what
soon will be a matter hours.
Now we are going to have the final phase of this project tended to;
the vacuuming and then recharging of the a/c system at which point all
OEM and newly integrated systems will be on line.
Here Victor carefully inspected and vacuumed the system
prior to placing a fresh load of R134A into her system. As the result of
this the final phase of this project has been completed as such she is
truly ready to travel home.
As with all projects a portion of them remain with us forever and in
the case of this gal because of her time with us and the extensive amount
of work completed she will be not only remembered but also missed as
the days roll by.
Sadly the weather is such that she had to be loaded in-between rain
showers while still drizzling under the cloak of darkness as such wonderful
pictures of her departing were not possible.
Here she is being secured within the transporter as her
trek home is about to begin. Even though at her core she remains the same
gal she has been completely revitalized, refreshed, and transformed; a
gal that her owner has yet to meet and yet we are certain that they will
play well together.
Thank you for visiting this web site. If you have any questions or comments please feel free to contact us. 866-365-0920
