<!--[if gte mso 9]><xml> <w:WordDocument> <w:View>Normal</w:View> <w:Zoom>0</w:Zoom> <w:TrackMoves/> <w:TrackFormatting/> <wunctuationKerning/> <w:ValidateAgainstSchemas/> <w:SaveIfXMLInvalid>false</w:SaveIfXMLInvalid> <w:IgnoreMixedContent>false</w:IgnoreMixedContent> <w:AlwaysShowPlaceholderText>false</w:AlwaysShowPlaceholderText> <woNotPromoteQF/> <w:LidThemeOther>EN-US</w:LidThemeOther> <w:LidThemeAsian>X-NONE</w:LidThemeAsian> <w:LidThemeComplexScript>X-NONE</w:LidThemeComplexScript> <w:Compatibility> <w:BreakWrappedTables/> <w:SnapToGridInCell/> <w:WrapTextWithPunct/> <w:UseAsianBreakRules/> <wontGrowAutofit/> <w:SplitPgBreakAndParaMark/> <wontVertAlignCellWithSp/> <wontBreakConstrainedForcedTables/> <wontVertAlignInTxbx/> <w:Word11KerningPairs/> <w:CachedColBalance/> </w:Compatibility> <m:mathPr> <m:mathFont m:val="Cambria Math"/> <m:brkBin m:val="before"/> <m:brkBinSub m:val="--"/> <m:smallFrac m:val="off"/> <m:dispDef/> <m:lMargin m:val="0"/> <m:rMargin m:val="0"/> <m:defJc m:val="centerGroup"/> <m:wrapIndent m:val="1440"/> <m:intLim m:val="subSup"/> <m:naryLim m:val="undOvr"/> </m:mathPr></w:WordDocument> </xml><![endif]--> Finally have some time to sit down and post this thread, been wanting to do it for months but as usual life gets in the way and each time I thought this project was finished, something else came up that kept me from considering it done. I’m happy to finally say, they are finished. I started development on these headers April of 2014, right after I had finished the M5 wagon build. What I thought was going to be just a few months of work, turned into almost a yearlong challenge, but absolutely rewarding in every aspect. By every definition I had underestimated the cost, effort, time, blood, sweat and tears required for such an endeavor. Going through this exercise though, gave me tremendous insight into what really goes into developing such a product. I had considered starting this thread in real time, posting up new progress as they happened, but that proved too tall an order with everything else that was on my plate. I suppose better late than never right?
So right about now, you’re asking yourself why? Why go through all this trouble and expense? The E39 M5 is an aging model, everyone else has moved on. Well, I don’t really care about everyone else. If you’re reading this, and you’re like me, we are not ready to move on and let go. In fact, we find every excuse to dump more money into the beast. I plan to keep my E39 M5 for as long as I can. We will all be probably driving electric vehicles in 10 years, but the legacy of the gasoline engined M5s will forever be a permanent part of my life.
About a year into the M5 wagon build thread, when I was refreshing the S62 that was to go into the wagon, I had a chance to study the Dinan headers that was also going into the wagon, since they were off the car collecting dust on my garage floor. As I observed the Dinan headers, I marveled at its complexity and quality. But as days and weeks passed, (during those staring sessions in the garage after dinner and before bed times - you know exactly what I’m talking about!) staring at them closely, I started seeing things, and asking questions. Why did they do it this way? Why didn’t they do it that way? Why is this thing like this? Why is this not like that? This was especially the case when I installed them for the very first time on my Anthracite M5, in my garage floor, on my back! Right about the same time, I had a set of Supersprint headers lying around from a parts car I purchased – same car where the S62 I used for the wagon came from. I also studied the Supersprint design and started asking a bunch of questions. Why 4 into 1? Why spring clamps? Why modular construction instead of solid 1 piece design like the Dinans? Why this? Why that? Why does the SS merge collector hang so low down on the car? Etc, etc. Also, at about the same time, I went with a group on a Saturday morning run up GMR where I had a chance to hold in my hands a set of Evolve headers that member threepedals (Allen) just purchased. Staring at the Evolve headers, first question popped on my mind was why aren’t these equal length? Where’s the stepping? Are these really made in the UK? Lots of questions indeed.
I don't consider myself an expert on the subject, far from it, but I’m not completely foreign with headers and header design. Prior to this project, I had been playing with 4 different set of headers on my E60 M5 (RD Sport, Agency Power, RPI and experimenting with my own variations). Previous to this, was playing with euro headers for my old E28 M5. Add in all the wrenching I’ve done in the garage for 20 years on BMWs; theory though, was learnt as I went, consulting with experts in the field and master fabricators. The rest, I just mix in the passion and love for the hobby.
After observing closely those 3 brands of headers mentioned above, I said to myself, “man, I wish there was a set of headers that had all the features I liked.” Also asked the question, “can there be any more improvements made over what is out there?” “Can it be done better?” I do believe in the equal length and tri-Y design of the Dinans, but I love the modularity of the Supersprints, I hate the 2-bolt flange type on the Dinans, I certainly didn’t like the quality of the Supersprints and the Evolves. I didn’t like that the Dinans were ceramic coated. I didn't like that the exit pipe was only 2.5" diameter. I didn’t like the that certain primary runners were angled so aggressively at the entry flange that the only way to screw in the nut was to move the entire header 1 mm at a time closer to the head, tighten the nuts 1mm, rinse and repeat. I really loathed the fact that the front subframe had to come down to install any type of headers. But the one big question that kept coming back to me was, could there still be unfound horsepower to be gained by improving the design? What if I were to combine all those features that I liked in the different headers and took out the features I didn’t like? I needed a stronger and more worthwhile reason to justify this whole exercise. Like…more power throughout the rev range? Is that a good enough of a reason? But how much more power can be had? And at what cost? Wouldn’t it be just ridiculously amazing if we get to that point? Such deep probing questions indeed.
We will know soon enough. Before I took out the Dinan headers out of my M5 wagon, I had a dyno test done to establish a baseline. I’ll post the dyno chart further down for the initial reference. This way, when I schedule the dyno test on these headers in the next few weeks, I’ll have a true delta measurement, without changing any other variable on the car. Just looking at pure header change only, was there a difference? Or did I just waste a whole year for nothing? Did I kill another M5 for naught? Did I just waste more money on a fruitless endeavor? Too many questions indeed.
In hindsight, I wish that I hadn’t “recycled” the 2 E39 Anthracite M5s back in 2012, they would have been perfect to use as fixtures for the header development. I guess I just didn’t look far enough in the future to know that I was going to need them. So with the decision made to build my own set of headers, I picked up another M5 around mid-2013. It was a multi-purpose purchase, I needed a complete roller as a fixture for header development, also needed another complete S62 powertrain for an M8 build that is currently under construction. I also needed some extra backseat leathers to finish my M5 wagon’s back seat, etc, etc. Lots of spares were needed, so as the saying goes, another M5 bites the dust. All the remaining parts were parted out, and so this poorM5 lives on in several M5s. It took about a month or so to gut out the car completely leaving it as a roller with engine, tranny and stock exhaust in place to begin header development.
Without disclosing too much, I’ll share with you we did. I’m sure you’ll understand if I leave out some details for obvious reasons. Working with a master fabricator, we gathered every spec I could find on the S62. Taking into consideration for the design the following:
Engine configuration
Maximum RPM range
Useable RPM
Peak HP/Peak Torque
Discplacement/Bore/Stroke
Compression ratio
Throttle body diameter
Intake/Exhaust port dimensions
Intake/Exhaust lift at valve
Intake/Exhaust duration at .050 lift
Intake/Exhaust opening at BBDC
Intake/Exhaust rocker arm ratio
Intake/Exhaust lobe centerline
Intake/Exhaust closure at ABDC
The specs above in addition to a few other considerations helped us determine all aspects that were built into the design. With my own wish list of features, we made the every effort possible to not leave anything out. In other words, if I was going to set out to build my own headers for the S62, here is my chance to incorporate everything I can and leave out things I don’t want. Another point I should mention was the issue of dropping the subframe to install headers. I wanted to see if I it was possible to install headers with the subframe in place, along with the steering box, steering column and hoses in place. The packaging constraints of the headers were many. If you are familiar with the lower part of the engine bay, there isn’t much room down there. Also, knowing that the exhaust ports on the S62 heads share the same pattern and size on the M60/M62 engines, I thought it would be great if these headers work for the 540i/740i brethren? Although I don’t know of any that would go as far as putting headers on those cars, but the possibility is there if one was looking for headers for those powerplants.
So, fast forward to today. My headers were designed and built for every reason you can think of and for no reason at all haha. Are these what unicorn dreams are made of? Who the hell knows. But I know that I’ve been dreaming of these headers for quite a while, and to see them finally a reality is absolutely astonishing. The big question remain unanswered until the dyno test. Very soon I'll post up what we find.
There you have it folks, some details on the unicorn headers, built from scratch. I’m sure you’ll understand if I do not disclose certain characteristics of the headers, let’s leave them as trade secrets.
4 -2 -1 (Tri-Y) modular design
True equal length runners
Full T304 Stainless Steel construction
100% Mandrel bent tubing
TIG welding, fully back purged w/ Argon
Solar Flux type B in cases where back purging is not applicable
Laser cut exhaust port flanges
Oversized exhaust ports to accommodate ported cylinder heads
3” V-band flange exit pipe
Profiled merge collectors
Double-slip joints w/ stainless steel spring clamps
Tuned stepping
Removal of front subframe not required for installation
100% of raw materials & supplies sourced from USA manufacturers. Mandrel bending, welding and fabrication services provided by USA vendors. In other words, these headers were 100% designed, built and assembled in the USA.
I’ll attach the pics I’ve taken during its development as well in subsequent posts. Enjoy!
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So right about now, you’re asking yourself why? Why go through all this trouble and expense? The E39 M5 is an aging model, everyone else has moved on. Well, I don’t really care about everyone else. If you’re reading this, and you’re like me, we are not ready to move on and let go. In fact, we find every excuse to dump more money into the beast. I plan to keep my E39 M5 for as long as I can. We will all be probably driving electric vehicles in 10 years, but the legacy of the gasoline engined M5s will forever be a permanent part of my life.
About a year into the M5 wagon build thread, when I was refreshing the S62 that was to go into the wagon, I had a chance to study the Dinan headers that was also going into the wagon, since they were off the car collecting dust on my garage floor. As I observed the Dinan headers, I marveled at its complexity and quality. But as days and weeks passed, (during those staring sessions in the garage after dinner and before bed times - you know exactly what I’m talking about!) staring at them closely, I started seeing things, and asking questions. Why did they do it this way? Why didn’t they do it that way? Why is this thing like this? Why is this not like that? This was especially the case when I installed them for the very first time on my Anthracite M5, in my garage floor, on my back! Right about the same time, I had a set of Supersprint headers lying around from a parts car I purchased – same car where the S62 I used for the wagon came from. I also studied the Supersprint design and started asking a bunch of questions. Why 4 into 1? Why spring clamps? Why modular construction instead of solid 1 piece design like the Dinans? Why this? Why that? Why does the SS merge collector hang so low down on the car? Etc, etc. Also, at about the same time, I went with a group on a Saturday morning run up GMR where I had a chance to hold in my hands a set of Evolve headers that member threepedals (Allen) just purchased. Staring at the Evolve headers, first question popped on my mind was why aren’t these equal length? Where’s the stepping? Are these really made in the UK? Lots of questions indeed.
I don't consider myself an expert on the subject, far from it, but I’m not completely foreign with headers and header design. Prior to this project, I had been playing with 4 different set of headers on my E60 M5 (RD Sport, Agency Power, RPI and experimenting with my own variations). Previous to this, was playing with euro headers for my old E28 M5. Add in all the wrenching I’ve done in the garage for 20 years on BMWs; theory though, was learnt as I went, consulting with experts in the field and master fabricators. The rest, I just mix in the passion and love for the hobby.
After observing closely those 3 brands of headers mentioned above, I said to myself, “man, I wish there was a set of headers that had all the features I liked.” Also asked the question, “can there be any more improvements made over what is out there?” “Can it be done better?” I do believe in the equal length and tri-Y design of the Dinans, but I love the modularity of the Supersprints, I hate the 2-bolt flange type on the Dinans, I certainly didn’t like the quality of the Supersprints and the Evolves. I didn’t like that the Dinans were ceramic coated. I didn't like that the exit pipe was only 2.5" diameter. I didn’t like the that certain primary runners were angled so aggressively at the entry flange that the only way to screw in the nut was to move the entire header 1 mm at a time closer to the head, tighten the nuts 1mm, rinse and repeat. I really loathed the fact that the front subframe had to come down to install any type of headers. But the one big question that kept coming back to me was, could there still be unfound horsepower to be gained by improving the design? What if I were to combine all those features that I liked in the different headers and took out the features I didn’t like? I needed a stronger and more worthwhile reason to justify this whole exercise. Like…more power throughout the rev range? Is that a good enough of a reason? But how much more power can be had? And at what cost? Wouldn’t it be just ridiculously amazing if we get to that point? Such deep probing questions indeed.
We will know soon enough. Before I took out the Dinan headers out of my M5 wagon, I had a dyno test done to establish a baseline. I’ll post the dyno chart further down for the initial reference. This way, when I schedule the dyno test on these headers in the next few weeks, I’ll have a true delta measurement, without changing any other variable on the car. Just looking at pure header change only, was there a difference? Or did I just waste a whole year for nothing? Did I kill another M5 for naught? Did I just waste more money on a fruitless endeavor? Too many questions indeed.
In hindsight, I wish that I hadn’t “recycled” the 2 E39 Anthracite M5s back in 2012, they would have been perfect to use as fixtures for the header development. I guess I just didn’t look far enough in the future to know that I was going to need them. So with the decision made to build my own set of headers, I picked up another M5 around mid-2013. It was a multi-purpose purchase, I needed a complete roller as a fixture for header development, also needed another complete S62 powertrain for an M8 build that is currently under construction. I also needed some extra backseat leathers to finish my M5 wagon’s back seat, etc, etc. Lots of spares were needed, so as the saying goes, another M5 bites the dust. All the remaining parts were parted out, and so this poorM5 lives on in several M5s. It took about a month or so to gut out the car completely leaving it as a roller with engine, tranny and stock exhaust in place to begin header development.
Without disclosing too much, I’ll share with you we did. I’m sure you’ll understand if I leave out some details for obvious reasons. Working with a master fabricator, we gathered every spec I could find on the S62. Taking into consideration for the design the following:
Engine configuration
Maximum RPM range
Useable RPM
Peak HP/Peak Torque
Discplacement/Bore/Stroke
Compression ratio
Throttle body diameter
Intake/Exhaust port dimensions
Intake/Exhaust lift at valve
Intake/Exhaust duration at .050 lift
Intake/Exhaust opening at BBDC
Intake/Exhaust rocker arm ratio
Intake/Exhaust lobe centerline
Intake/Exhaust closure at ABDC
The specs above in addition to a few other considerations helped us determine all aspects that were built into the design. With my own wish list of features, we made the every effort possible to not leave anything out. In other words, if I was going to set out to build my own headers for the S62, here is my chance to incorporate everything I can and leave out things I don’t want. Another point I should mention was the issue of dropping the subframe to install headers. I wanted to see if I it was possible to install headers with the subframe in place, along with the steering box, steering column and hoses in place. The packaging constraints of the headers were many. If you are familiar with the lower part of the engine bay, there isn’t much room down there. Also, knowing that the exhaust ports on the S62 heads share the same pattern and size on the M60/M62 engines, I thought it would be great if these headers work for the 540i/740i brethren? Although I don’t know of any that would go as far as putting headers on those cars, but the possibility is there if one was looking for headers for those powerplants.
So, fast forward to today. My headers were designed and built for every reason you can think of and for no reason at all haha. Are these what unicorn dreams are made of? Who the hell knows. But I know that I’ve been dreaming of these headers for quite a while, and to see them finally a reality is absolutely astonishing. The big question remain unanswered until the dyno test. Very soon I'll post up what we find.
There you have it folks, some details on the unicorn headers, built from scratch. I’m sure you’ll understand if I do not disclose certain characteristics of the headers, let’s leave them as trade secrets.
4 -2 -1 (Tri-Y) modular design
True equal length runners
Full T304 Stainless Steel construction
100% Mandrel bent tubing
TIG welding, fully back purged w/ Argon
Solar Flux type B in cases where back purging is not applicable
Laser cut exhaust port flanges
Oversized exhaust ports to accommodate ported cylinder heads
3” V-band flange exit pipe
Profiled merge collectors
Double-slip joints w/ stainless steel spring clamps
Tuned stepping
Removal of front subframe not required for installation
100% of raw materials & supplies sourced from USA manufacturers. Mandrel bending, welding and fabrication services provided by USA vendors. In other words, these headers were 100% designed, built and assembled in the USA.
I’ll attach the pics I’ve taken during its development as well in subsequent posts. Enjoy!
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