Blackknight530i 530i6 -> M5 Conversion Build Thread - Page 5 - BMW M5 Forum and M6 Forums
E39 M5 and E52 Z8 Discussion 1998-2003 Advertiser's Forum

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post #41 of 112 Old 3rd October 2016, 07:32 PM Thread Starter
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Alright, a little update after the first track event after the build completed just a few weeks ago. I finally got the brackets I ordered on Friday afternoon and had them swapped out in about 20-30 minutes and got on the road up to VIR. I met up with my friend Andy who just got his M2 over the 1200 mile break-in period and had the Dinan intake and exhaust installed on the way and we convoyed up there. I kept having the same clunk and it was really not fun the whole way up, but only seemed to be apparent during slower speeds up to around 55 or so, but weren't bad around 80 or so where we were most of the way.

I wasn't able to take another look at it that night, but I did take a look at the bumper to see if anything plastic in there was shaking around and causing noises. I immediately noticed that the right side fog light was secured on the inside edge (with screws), but the outside part was flapping around like crazy. Removed the fog light and found the bracket that mounts to the bumper to hold the fog light had come off and was just sitting inside there. I pulled it out as well. I checked the other side and noticed that the alternator cooling duct (not used anymore) was loose and so I pulled that out as well, which unfortunately left the brake cooling duct loose, but I couldn't do anything about that at 10pm in the hotel parking lot, so I left it. In the morning on the way to the track, the clunking was still there. Ugh!

After borrowing a jack, jack stand and some tools from our neighbors, I found out the culprit. It turned out that the nut on the idler arm pivot bolt was loose and allowing the whole tie rod to slide around. At first I thought that I just didn't tighten it properly when building it, but now I'm not so sure. I got the bolt tightened up (only needed 35 lb-ft) and got it back on the ground, but now it had a loud popping when turning the wheel to the right and back. I concluded that it was likely a strut bearing going bad and we went ahead and did the track weekend. The car was fantastic all weekend. No more clunking and the car handled great, accelerated great, and just overall performed great. I didn't notice the popping at all on the track, just a couple times getting around the paddock. The brakes were still 530i brakes with OE pads, which showed their weakness very quickly. Brake fade was a big concern all weekend, so I wasn't able to go full throttle on the straights. I kept it under 120 MPH and mostly 110 MPH, since braking would suffer with any faster speeds. The car could easily go a lot faster though. I think 140+ would have been easily attainable if I had the braking confidence. I'll be putting the M5 brakes I have on soon, and I'll find some good track pads for the next event. I also hadn't replaced the rear struts with the M5 Konis yet, so it could probably have benefited from the stiffer suspension back there.

Once I got back home, I decided to get the car up in the air to take a better look. It turned out it was the ball joint on the center link on the passenger side rubbing the subframe. I was flabbergasted as to how that was possible. After a quick search, I found out that there is actually a way you can install the center link backwards (right to left), and it looked like I did just that. Unfortunately, it has worn through the boot pretty bad on the passenger side, so I'll need to order a new one and FCP should be able to refund me for the broken one. Since I'll be gone all week it should be in by the weekend when I can work on it after I get back.

I also finally got the bolts and everything I need to install the M5 torsion bars, so maybe next Sunday after I get the center link swapped, I'll do the subframe bushing replacement and install the bars.

Here's my car with Brian's M3T and M5T/SC that we built together:



My buddy's M2 in Long Beach Blue:



Another buddy's F10 M5 in Alpine White:


-Paul
2003 "M5" - S62/420g swap, M5 diff, M5 driveshaft, M5 brakes, M5 Traction Bars, Eibach Sway Bars, UUC Evo3/DSSR, Custom Exhaust,
BMW NBT Retrofit, M5 Gauge Cluster, Hella G4 Bi-Xenon Retrofit, M5 Extended Leather Interior Swap, APEX PS-7s, e60 Hubs, Koni Sports
Coming Soon - M5 Bumpers
530i 6-speed swap build thread

2003 530it6 - M54b30/S6S-420g swap, 3.15 540it diff, e60 SSK, VMR VB2 19" Wheels, M5 Gauge Cluster, Hella G4 Bi-xenon Retrofit, NBT Retrofit, Koni Sports, 540i Brakes

2001 749i6 - Retired and being parted out - M5Board Build Log

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post #42 of 112 Old 3rd October 2016, 09:16 PM
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post #43 of 112 Old 3rd October 2016, 09:17 PM Thread Starter
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Awesome!! I bet that was a lot of fun!
It was a total blast. Brian was my instructor, and he's really good at it.

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-Paul
2003 "M5" - S62/420g swap, M5 diff, M5 driveshaft, M5 brakes, M5 Traction Bars, Eibach Sway Bars, UUC Evo3/DSSR, Custom Exhaust,
BMW NBT Retrofit, M5 Gauge Cluster, Hella G4 Bi-Xenon Retrofit, M5 Extended Leather Interior Swap, APEX PS-7s, e60 Hubs, Koni Sports
Coming Soon - M5 Bumpers
530i 6-speed swap build thread

2003 530it6 - M54b30/S6S-420g swap, 3.15 540it diff, e60 SSK, VMR VB2 19" Wheels, M5 Gauge Cluster, Hella G4 Bi-xenon Retrofit, NBT Retrofit, Koni Sports, 540i Brakes

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post #44 of 112 Old 3rd October 2016, 09:29 PM
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Looks like Brian was trying to get more flow through the lower inlet by blocking off the brake ducts -- good move, but that beast is going to need a substantial external oil cooler (and removal/block off of the factory oil-to-water one) to shed the monstrous amount of heat it generates on track at high duty cycle while making 600+ hp.

Current stable:

2001 M5 LeMans Blue/Silverstone
Dinan: springs, Konis, rear sway bar, monoball bushings;
Ground Control camber plates, Brake ducts opened, Evolve tune,
OE 9.5" rear wheels all around & 275/35-18 Pilot Super Sport


2011.5 M3 sedan 6MT Silverstone, slicktop
Dinan front swaybar, Eibach rear swaybar, pins-out-max-camber-up-front, BFG Rivals autox/Michelin PSS street/Nitto NT-01 time trials

2007 328i wagon Silver/gray
2006 330i E90 ZSP 6MT Electric Red/Black
1975 CanAm 125MX2
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post #45 of 112 Old 3rd October 2016, 09:32 PM Thread Starter
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Looks like Brian was trying to get more flow through the lower inlet by blocking off the brake ducts -- good move, but that beast is going to need a substantial external oil cooler (and removal/block off of the factory oil-to-water one) to shed the monstrous amount of heat it generates on track at high duty cycle while making 600+ hp.
Yeah, I think that's what he was trying to do. I think he's got that advice already for the oil cooler and block-off, but I think he's deciding to keep that car off the track. He's only at 505whp, so not quite 600+, but still. It's totally fine in normal around town driving, just gets hot on track. Temps come down really quick though after letting off a bit.

-Paul
2003 "M5" - S62/420g swap, M5 diff, M5 driveshaft, M5 brakes, M5 Traction Bars, Eibach Sway Bars, UUC Evo3/DSSR, Custom Exhaust,
BMW NBT Retrofit, M5 Gauge Cluster, Hella G4 Bi-Xenon Retrofit, M5 Extended Leather Interior Swap, APEX PS-7s, e60 Hubs, Koni Sports
Coming Soon - M5 Bumpers
530i 6-speed swap build thread

2003 530it6 - M54b30/S6S-420g swap, 3.15 540it diff, e60 SSK, VMR VB2 19" Wheels, M5 Gauge Cluster, Hella G4 Bi-xenon Retrofit, NBT Retrofit, Koni Sports, 540i Brakes

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post #46 of 112 Old 3rd October 2016, 09:44 PM
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Yeah, I think that's what he was trying to do. I think he's got that advice already for the oil cooler and block-off, but I think he's deciding to keep that car off the track. He's only at 505whp, so not quite 600+, but still. It's totally fine in normal around town driving, just gets hot on track. Temps come down really quick though after letting off a bit.
Yep, that was me; I was telling him about the block off bypass plate and using an external cooler. Unfortunately, there really isn't a great spot for one that can be easily and properly ducted on the E39, but it can and has been done.

I'm glad you guys had a fun and successful weekend and that center track rod issue didn't bite anyone.

Current stable:

2001 M5 LeMans Blue/Silverstone
Dinan: springs, Konis, rear sway bar, monoball bushings;
Ground Control camber plates, Brake ducts opened, Evolve tune,
OE 9.5" rear wheels all around & 275/35-18 Pilot Super Sport


2011.5 M3 sedan 6MT Silverstone, slicktop
Dinan front swaybar, Eibach rear swaybar, pins-out-max-camber-up-front, BFG Rivals autox/Michelin PSS street/Nitto NT-01 time trials

2007 328i wagon Silver/gray
2006 330i E90 ZSP 6MT Electric Red/Black
1975 CanAm 125MX2
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post #47 of 112 Old 3rd October 2016, 09:47 PM Thread Starter
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Yep, that was me; I was telling him about the block off bypass plate and using an external cooler. Unfortunately, there really isn't a great spot for one that can be easily and properly ducted on the E39, but it can and has been done.

I'm glad you guys had a fun and successful weekend and that center track rod issue didn't bite anyone.
Yeah, considering that we didn't turn the wheel much on track, it really didn't pose an issue. Even on the drive home, there were like 2 times where it rubbed, leaving the paddock at slow speed and when I stopped for dinner. Any other time I was driving relatively straight, so it didn't do much damage. I'm betting the joint is still fine, but that most of the grease has a way to get out now. I could try to flip the center link around before heading to the beach tomorrow, but I don't see much point, since the alignment will likely be slightly off and I'll just need to do it again when I get the new one, so I'll wait. I'll either ride with my friend or take the wagon.

-Paul
2003 "M5" - S62/420g swap, M5 diff, M5 driveshaft, M5 brakes, M5 Traction Bars, Eibach Sway Bars, UUC Evo3/DSSR, Custom Exhaust,
BMW NBT Retrofit, M5 Gauge Cluster, Hella G4 Bi-Xenon Retrofit, M5 Extended Leather Interior Swap, APEX PS-7s, e60 Hubs, Koni Sports
Coming Soon - M5 Bumpers
530i 6-speed swap build thread

2003 530it6 - M54b30/S6S-420g swap, 3.15 540it diff, e60 SSK, VMR VB2 19" Wheels, M5 Gauge Cluster, Hella G4 Bi-xenon Retrofit, NBT Retrofit, Koni Sports, 540i Brakes

2001 749i6 - Retired and being parted out - M5Board Build Log
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post #48 of 112 Old 3rd October 2016, 10:01 PM
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post #49 of 112 Old 3rd October 2016, 10:21 PM
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Happy to be alive! Lol


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Wait, isn't that what you're planning to say if you stay past Friday at the beach?

Current stable:

2001 M5 LeMans Blue/Silverstone
Dinan: springs, Konis, rear sway bar, monoball bushings;
Ground Control camber plates, Brake ducts opened, Evolve tune,
OE 9.5" rear wheels all around & 275/35-18 Pilot Super Sport


2011.5 M3 sedan 6MT Silverstone, slicktop
Dinan front swaybar, Eibach rear swaybar, pins-out-max-camber-up-front, BFG Rivals autox/Michelin PSS street/Nitto NT-01 time trials

2007 328i wagon Silver/gray
2006 330i E90 ZSP 6MT Electric Red/Black
1975 CanAm 125MX2
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post #50 of 112 Old 4th October 2016, 01:59 AM Thread Starter
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Good news guys! I decided to go ahead and fix the center link. I figured I would go ahead and remove it and at least assess how bad it was damaged, but while I had it out, I discovered that the part of the boot that had rubbed was right over a solid plastic part under it and wasn't letting any grease out at all. It isn't pretty, but at least it's not leaking and seems like it will be fine. I got it turned around and swapped the tie rod ends over, but kept the amount of threads on the respective side, so as to hopefully not change the alignment much. After I took it out, it was obvious how it could be installed backwards, so I'll need to make sure to install it the right way in any future installs, but unfortunately, the Lemforder center link was not marked in the direction it's supposed to go. The only indication I think will tell you is that there is some writing in the middle of the bar that on mine is facing the front of the car. I can't say with certainty that any other one will have the printing in the same place though.

After all was said and done, I backed the car forwards and back and the steering was straight. Then I checked turning lock to lock and there were no popping sounds. I'd say job well done... finally! Looks like I will be able to drive the car to the beach this week after all .

-Paul
2003 "M5" - S62/420g swap, M5 diff, M5 driveshaft, M5 brakes, M5 Traction Bars, Eibach Sway Bars, UUC Evo3/DSSR, Custom Exhaust,
BMW NBT Retrofit, M5 Gauge Cluster, Hella G4 Bi-Xenon Retrofit, M5 Extended Leather Interior Swap, APEX PS-7s, e60 Hubs, Koni Sports
Coming Soon - M5 Bumpers
530i 6-speed swap build thread

2003 530it6 - M54b30/S6S-420g swap, 3.15 540it diff, e60 SSK, VMR VB2 19" Wheels, M5 Gauge Cluster, Hella G4 Bi-xenon Retrofit, NBT Retrofit, Koni Sports, 540i Brakes

2001 749i6 - Retired and being parted out - M5Board Build Log
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