Building an 'M540' out of an E34 530i 5 speed - Page 6 - BMW M5 Forum and M6 Forums
E34 M5 Discussion 1988-1995 Sedan and Touring

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post #51 of 186 Old 3rd October 2013, 08:39 AM Thread Starter
AseanAero
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M60B40 work before installation

M60B40 work before installation

I want to start shopping for parts to get the B40 ready for installation.

The engine appears to be very low mileage , it has supposedly come out of a Singapore based 840 coupe.

Most of the missing parts on the B40 I can swap over from my B30 engine;

- Exhaust manifolds

- air cond compressor

- Clutch and flywheel (0.5" smaller diameter but will bolt on from what I have read)

- ECU (re-chipped)

- ICV

I need to buy a B40 MAF and intake duct to the throttle body (throttle body is there)

For new gaskets

- Cam covers

- Intake manifold (all gaskets)

- Valley gasket (under the intake)

- Sump gasket

I'll have a look at the main bearings, timing chain and oil pump bolts when I get the engine on the engine stand, the motor turns over nicely by hand, not to easy and not too hard.

Anything else while I have the engine on the engine stand ?



Tony, Aussie expat in Jakarta Indonesia

1990 E34 M5 S38B36 GA25324
GA25324


1995 E34 540/5 Project
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post #52 of 186 Old 3rd October 2013, 02:46 PM Thread Starter
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Exhaust mods

Started building a Y dump pipe from 110mm dia exhaust pipe between the headers and the centre muffler.

Front mufflers have already been removed.

The Y pipe will accept the 2 exhaust pipes from the back of the exhaust manifold before they join into 1 (2 to 1)

The pipe will be pressed into an oval shape 60mm height.

So the final exhaust will be

- 4 outlets from the exhaust manifold to the Y pipe

- gutted (no packing) centre muffler.

- used E34 M5 muffler.

It should be a very low restriction system.

The exhaust as it is now is actually quiet from idle to 2,500rpm , sporty from 2,500 to 4,000 and wails above 4,000rpm. No booming in the cabin at all.

So far I'm pleased with the results



Tony, Aussie expat in Jakarta Indonesia

1990 E34 M5 S38B36 GA25324
GA25324


1995 E34 540/5 Project

Last edited by AseanAero; 4th October 2013 at 07:44 AM.
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post #53 of 186 Old 3rd October 2013, 02:47 PM Thread Starter
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Double post



Tony, Aussie expat in Jakarta Indonesia

1990 E34 M5 S38B36 GA25324
GA25324


1995 E34 540/5 Project

Last edited by AseanAero; 3rd October 2013 at 02:50 PM.
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post #54 of 186 Old 4th October 2013, 07:42 AM Thread Starter
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Fabricating the front exhaust

I couldn't buy oval section exhaust pipe so we're making it out of 110mm dia truck pipe by pressing it in the hydraulic press

It needs 2.5 tonnes of force to press

Final height will be 75mm (3 inches)

I'm trying to achieve a pressure wave terminator box which should be at least 8 times the volume of a single cylinder.

The volume of this chamber is 8.55 litres, this delivers a 22:1 ratio with the B30 and a 17:1 ratio with the B40.

I read about this years ago in David Vizard's book on Chev V8s and exhaust systems, this is my first attempt at building one so I'm not sure what the results will be but for $40 in materials and a bit of cutting and welding it's worth a try.

Going to do some acceleration runs with Taffy's G-Tech to see if there's any difference before and after.

.
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Tony, Aussie expat in Jakarta Indonesia

1990 E34 M5 S38B36 GA25324
GA25324


1995 E34 540/5 Project

Last edited by AseanAero; 4th October 2013 at 03:15 PM.
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post #55 of 186 Old 4th October 2013, 10:01 AM Thread Starter
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Existing front exhaust set up

Existing front exhaust set up and where the termination box is going
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Tony, Aussie expat in Jakarta Indonesia

1990 E34 M5 S38B36 GA25324
GA25324


1995 E34 540/5 Project
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post #56 of 186 Old 5th October 2013, 04:12 PM Thread Starter
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This section of dual pipes will be replaced with a 140 x 75mm oval section single pipe going straight into the centre muffler.



Tony, Aussie expat in Jakarta Indonesia

1990 E34 M5 S38B36 GA25324
GA25324


1995 E34 540/5 Project
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post #57 of 186 Old 7th October 2013, 12:05 PM Thread Starter
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Big bore Y pipe done, it will be fitted this week.

A bit rough around the edges but ok for an experiment.

Can anyone suggest a freeware or inexpensive CAD package for the Mac ?

I don't want anything fancy, just something to produce cutting templates for pipe and other shapes

Weight is 13kg, about the same as the original pipes and 2 mufflers (already removed), I may save 2kg, I'll know when I weigh the pipes I remove

I used 2mm wall thickness pipes to reduce drumming and vibration, I could have gone a lighter gauge pipe but worried about acoustic drumming in the passenger cabin.

Pipe cross section is almost double the twin OEM pipes



.
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Tony, Aussie expat in Jakarta Indonesia

1990 E34 M5 S38B36 GA25324
GA25324


1995 E34 540/5 Project

Last edited by AseanAero; 7th October 2013 at 12:59 PM.
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post #58 of 186 Old 9th October 2013, 04:51 PM Thread Starter
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Big bore Y pipe

.

Y pipe tacked into place today.

It will be fully welded and installed tomorrow by my workshop minions.

I get to try it out on Saturday when I get back to town.

Slight interference with the LHS transmission mount which will be dimpled for clearance

Lots of leaks as it isn't welded up yet but so far it sounds awesome.

4 into 2 Y pipe, standard 530 centre muffler with packing removed but baffles still in place, used E34 M5 muffler (standard)

I'll do a video on Saturday and upload it.

The M60B30 has started having a major coolant leak from the back of the block so the M60B40 swap will happen sooner than planned.

Looks like I have to replace the valley pan gasket and rear coolant cross over gaskets I may as well spend an extra few days and do the swap.

Taffy asked tonight why nobody has thought of this before, I can't say I've ever seen it on a BMW, anyone ?


.
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IMG_00000850.jpg   IMG_00000849.jpg   IMG_00000845.jpg   IMG_00000846.jpg   IMG_00000848.jpg  




Tony, Aussie expat in Jakarta Indonesia

1990 E34 M5 S38B36 GA25324
GA25324


1995 E34 540/5 Project

Last edited by AseanAero; 9th October 2013 at 05:21 PM.
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post #59 of 186 Old 9th October 2013, 05:17 PM
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Cool

GREAT SOUND !

Very deep V8 ... used to be muffled sound like a 6-cyl.
Now the sound is very deep. Sounds like a real V8

It is said that if you line up all the cars in the world end to end, someone would be stupid enough to try and pass them.
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post #60 of 186 Old 9th October 2013, 06:13 PM Thread Starter
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As the two chambers are joined together I don't think it needs a balance pipe but happy to be corrected.



Tony, Aussie expat in Jakarta Indonesia

1990 E34 M5 S38B36 GA25324
GA25324


1995 E34 540/5 Project
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