Really long day today. First I got started with trying to figure out what's causing a clunk from the front end when driving straight over somewhat rough roads.
First I assumed it was the wiring for my xenon fog lights that might be swinging around and hitting the fender liners, but really, they didn't make noise before the swap. I zip tied them anyways, just to test it out. Unfortunately, this didn't fix it.
Next thing I decided to try was replacing the subframe bolts with actual M5 ones. When we did the swap, I had assumed that the I6 bolts would work the same way on the V8 subframe, but I was mistaken. Brian had a bunch of bolts in his collection, so we found some that would work. It turned out, all but 1 were actual 540/M5 subframe bolts. Anyways, I replaced them all and torqued them to spec. Still didn't fix the clunk.
I noticed that when the car was on the ground and I pressed down on either side, I could hear a double-clank sound coming from around the middle of the engine area. I had checked all the control arm bolts, sway bar bolts, steering bolts, etc. for any looseness, but couldn't find anything. I decided to do a quick search and see if anyone else had a clunk like mine. It turns out the first thread I found was from Topaz540i and he described an almost identical issue. His turned out to be the sway bar endlinks and how they were mounted. I think he put the washer in the wrong place. He said once he put the washer between the endlink and the strut attachment point and cranked them down really tight, it fixed his problem. I went to look at mine and sure enough, I had put the washer on the sway bar end, not the strut end. I swapped the bushing to the correct location and cranked it down, but it still didn't fix the clunk. I'm honestly at a loss on this. Someone did mention that when the washer is missing, it allows the threaded part of the endlink to wallow out the hole a bit, so maybe I just need to get new brackets and try that. I did notice that when the wheels are turned to either side, the clunk is gone, so I'm pretty sure it's sway bar related, as it would be loaded during a turn.
Anyways, on to the other stuff I did today. I finally got around to installing the extended leather dash and center console. This is a very time consuming process, but not altogether difficult. The results are pretty amazing. I could have sworn I got the lower driver side dash from Trevor, but I wasn't able to find it in my house, so I may have forgotten to grab it. I'll probably end up having to put the vinyl one in for this weekend's HPDE at VIR, but that's not a big deal. While I had the console out, I decided to run the wiring for the sport button and swapped the switch center for the one from my e38. It has the buttons for heated seats, and my seats are heated, but I need to retrofit the wiring for them. I also decided to wire up the servotronic on the steering box. I cut the connector off the e38 and ran 2 new wires up the tray under the driver side air box, into the bin with the brake master cylinder, then across the firewall in the cowl covering the engine wiring harness and wiper motors, then into the ebox. I did basically the same thing for the oil pressure switch before. With the Tesa tape, it looks factory installed
The last thing I did was to do the white LED swap into my custom made black face M5 cluster. I had been putting it off for a long time, but since I was taking the whole dash apart anyways, I figured now was as good a time as any. It looks amazing. This is a pic of the one in my wagon, but it looks the same: