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Wow cant wait till its finished , this is a crazy build!
 
I saw this article in the latest Bimmer magazine that came in the mail. The build had some extensive fabrication done, makes my build look like childsplay. I swear these europeans are intrepid and creative custom builders...absolute works of art.
I would not say that your on that level speaking off experience it takes time and patience to do what we do especially when you want it done a certain way don't fell bad that its taking you some time to do I have been working on my 8 series for 7 years I drove that car 3 times lol. Keep up the good wrenching. :applause:
 
Discussion starter · #303 ·
Rear Subframe Reassembly

Finally the weekend is here, time to play!!! Happy Friday everyone!!!

- Did a bit of scrubbing of the rear sub-frame, not at the level of Mr. Socale39 (Justin) but good enough that the aluminum is gleaming again.
- Finally installed the 3.62 LSD and set torque, I had replaced the diff fluid with Redline 75w90 Gear Oil at one point months ago so no need to do that again.
- Holding off on replacing the rear sub-frame bushings for now but plan to replace them before bolting up the sub-frame to the car.
- Interesting side note: rear axles of the M5 are significantly beefier than the 540i.
- Installed the M5 rear wheel bearings to the wheel carrier and all the pertinent suspension components.
- Re-installed Bilstein Sport Shocks that were purchased new last year for the project
- Installed Dinan RSB with the Beastpower brackets.

Rear Sub-Frame is assembled!

All the nuts and bolts are on finger tight, I prefer not to torque down all the suspension bits while the sub-frame is out. Once the whole assembly is back on the car, I'll set the torque on all the fasteners.
 

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Discussion starter · #304 ·
Rear Brake Dust Shields

Some slight fabrication required to install the M5 rear brake dust shields. Since I'm installing a BBK and the rear rotors are 355mm, the stock 540i rear dust shields are way too small, but the plus side is that the cutouts for the caliper and the e-brake cable are compatible with the 540i wheel carrier. On the other hand, the M5 rear dust shields are large enough to accommodate the 355mm rotors but the cutouts for the caliper and e-brake cable are in the wrong location in relation to the wheel carrier. I don't have pics of the 540i dust shields since I threw them away - I just might regret this!!!

540i dust shield: trailing rear calipers - 9 o'clock position, forward (leading) e-brake cable cutout - 3 o'clock position
M5 dust shield: trailing rear calipers - 9 o'clock position, top e-brake cable cutout - 12 o'clock position

Obviously life would be simpler if I can just do away with the rear dust shields like at the fronts, but the rear dust shields also provide a mounting plate of sorts for the whole e-brake assembly to work properly. I kept the old dust shields from when I had my Brembo BBK mounted to the sedan. You can see in the pics where they were cut to accommodate the larger Brembo caliper. I thought of reusing these for the Rotora 4 pot rear calipers, but I run into the same issue of the e-brake cable cutout location. I have a feeling that I will need to order a pair of new 540i dust shields and that the M5 dust shields won't work. The fix is easy enough, simply cut off the edge on the 540i dust shield so it clears the 355mm rotor.

I can't really finish up this part of the project since the complete sub-frame has to be on the car so I can use the e-brake cable to assemble the entire e-brake system.
 

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Discussion starter · #305 · (Edited)
Trunk Floor Surgery Prologue

So below are the 2 images I lifted from realoem.com. First image is the M5 trunk floor, second image is the wagon's floor. The basic idea is to replace the wagon's spare wheel well floor with that of the M5's trunk floor. Why? To take advantage of the natural mounting positions of the dual exhaust system and to relocate the battery to the center trunk floor. I've lost count of how many hours I spent just staring at the floors to figure out the easiest and most painless way to do this...there isn't!!!

I've been working on this last phase for about a week and I think that if I do this again, it would be better to make this the very first phase of the project right at the moment when the wagon is completely stripped down to the shell, with nothing around to get damaged or dirty. Thinking back, I did plan to tackle it before the wiring phase, but decided to push it back (read: closet procrastinator). On the contrary, I have most of the interior completely assembled, including the alcantara headliner, so now I have to carefully work around the area so not to damage anything. Also have to cover and protect all the sensitive wires since there will be lots of cutting, drilling and grinding. Its a very messy phase, dust and smoke gets everywhere. Grinding off the rubber glue/insulation to reveal all the spot welds is just nasty. I am scared, terrified to use only one tool in my garage, the "finger cutter" angle grinder and this part of the project relies on extensive use of this tool.

I broke down this undertaking into smaller steps so it won't be so overwhelming:

1. Trim the trunk floor bulk cut down to the essential pieces I will reuse
2. Remove the sheet metal on the wagon that will be replaced by the M5 parts
3. Test fit everything
4. Call and schedule welder
5. Rust proof all disturbed areas
6. Take another vacation

Thinking back again to the idea if there was an easier way, yes. Instead of salvaging the sedan's trunk floor, one can simply buy all the pertinent sheet metal new and weld them together. This way you avoid half of the difficult work. But then you run into the problem of having to build a jig for it. If you're even 1mm off in aligning your newly purchased sheet metal at the time of welding, everything will be off and nothing will mount properly aligned. Money and time wasted. The benefits of reusing the sedan's trunk floor is that obviously, you save a boatload of money and all the panels that you need for the conversion are already welded together from the factory, all perfectly aligned. Just need to add some surgical cutting precision and lots of patience and cases of elbow grease. Time to buckle down and get cracking...I do hope I will still have all my fingers intact and undamaged after all this!!!
 

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Discussion starter · #306 ·
Trunk Floor Surgery Step 1

Trimming the fat...

Ok fellas, this is where the men are separated from the boys, cowboys separated from the cowgirls, tinkerers from the tallywhackers, a pint of Ben & Jerry's from a bag of otter pops, alright alright, you get the picture.

Lots of pics of the not so glamorous part of the project. So pretty basic here...grind, strip, drill, pry, grind, strip, drill, pry. Rinse and repeat another 500 times.
 

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And I thought I was crazy!

This has got to be one of the coolest builds ever.

And the wagon is so stealthy. I hit a local speed trap this morning in my 540iT going about 40 mph in a 30 mph zone; and thought for sure I was going to get busted. Instead, because I looked like a respectable citizen in his wagon heading to work, they let me pass!
 
Discussion starter · #312 ·
Thank you everybody for the kind words and encouragement!!! It's very welcome and very well received. I am absolutely due for an update and have been sporadically working on the project the past month. As usual, life gets in the way and the project gets pushed back a bit. Hopefully I will have some time next week to post more updates, I do have some good progress to report. Sit tight!
 
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Any updates??? Can't wait to see some videos...
 
Discussion starter · #316 · (Edited)
The saga continues...

Awfully quiet here, you can almost hear the crickets and the cobwebs grow.

Firstly, some housekeeping stuff:

- Ended up taking a summer hiatus from this project, not so much due to the summer heat like last year, but rather due to getting involved with other unforeseen projects.
- Early in the summer I found the Ronin M5 ('93 M5) and bought it, and well, couldn't help myself building it up and took most of my free time.
- Also picked up another E39 M5 and been playing with that.
- Did a bit more shopping for the wagon project, mainly more wheels, set of springs.
- And for those that frequent the Parts for sale section, I did some garage purging as well.
- Kinda sorta have a place now to do all my projects, personal and clients' builds.

So the summer wasn't that quiet for me.

I'm at a Ducks game right now but will post pics when I get home tonight.

Go Ducks!!!

Oh yeah, almost forgot...loads of updates on the wagon build coming up. I have the ghetto version of the auto guide app on my phone so I can't upload pics.
 
- Early in the summer I found the Ronin M5 ('93 M5) and bought it, and well, couldn't help myself building it up and took most of my free time.
where is that thread!!!? :eek:h:


I'm at a Ducks game right now but will post pics when I get home tonight.

Go Ducks!!!
Ducks suck. Go Sharks!!!
 
Discussion starter · #318 ·
where is that thread!!!? :eek:h:




Ducks suck. Go Sharks!!!


I can barely keep up with this thread, so no build thread yet for the Ronin M5. But for instant gratification, please click on link below:

http://www.flickr.com/photos/55891776@N04/sets/72157635359765634/


Lol, yeah Ducks suck, especially now that Selanne is retiring. And not too excited about the Lakers season either, KB's Achilles injury might not get him back like he was before.






Sent from AutoGuide.com Free App
 
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Wow Jed! Check you out man! I gotta drive up and see it in person. So that's why you don't call or write anymore :hihi:
 
Discussion starter · #320 ·
Wow Jed! Check you out man! I gotta drive up and see it in person. So that's why you don't call or write anymore :hihi:

Haha, sup homie!

Yeah, seems like I get more action with the E39 than the E60. You should see the poor thing, it has a nice thick layer of dirt and cobwebs everywhere. We need to do another run soon, I barely put miles on the V10 this year.
 
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