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Just another E39 M5 LS swap, but with 2 snails...

80K views 166 replies 69 participants last post by  yourunifly 
#1 · (Edited)
I figured I might as well get this thread rolling.

Disclaimer: This is a PROJECT CAR. I am in no rush, so please don't post complaints about how long it is taking me to do this. LOL. I am a busy guy, and have a family, so this project is not the center of my world.

When I sold my other M5, my plans were to buy an M4 or a 911TT, but Clemster called me and told me about this car and made me an offer I couldn't refuse. I've always loved the M5, but I wanted 700+hp. Instead of spending $30k on an S62 engine, I spent $175 on an LS.

Thanks to Clemster, rao, Herrubermensch, and all of my other friends who have helped me out with this.....

Stats:
2003 BMW M5
5.3L iron block LS - brand new stock internal rebuild from the ground up
799 heads - fresh valve job and all BTR goodies here too.
BTR twin turbo cam
T56 transmission
Twin 68mm turbos (CX Racing, aka, cheap turbos)
Tial MVR 44mm wastegates
Tial Q BOV's
I will run a meth system of some kind

Shooting for 700-800hp at the wheels.

The M5 - Sterling Gray, Executive Caramel Leather interior. (Thanks to Clemster for the hook up)






The egine: 5.3L LS from a 2005 Tahoe.


The foam LS block for fitting..... It is an exact replica of an LS engine, with heads, bolt holes, the whole thing. Pretty sweet.


I used an i6 subframe, so I had to source some additional parts.....




I moved the cross support forwards about an inch to clear the oil pan.


Other parts

68mm liquid and oil cooled turbo


Tial Wastegate


The awesome Ford Taurus fan:



I will be updating this thread as the project goes along. I have a lot of pictures. So this will take some time.....
 
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#41 ·
These iron LS units are awesome, more bang-for-buck than just about anything else; which is why one can find these stuffed into just about everything from Miatas on up. They kind of remind me of Toyota JZ-series iron engines that also were close to invincible.

I am curious how handling of car turns out with LS iron power. With iron block and induction add-ons, I'd guess hundred or so kilos heavier up front than stock S62?
 
#42 ·
The JZ motor, which really is amazin, but you don't have any real power into 6k rpms. Making it GREAT for the track, but boring for daily driving. One of the members here built the wide body 2JZ swap and sold it because he didn't like the off boost experience. I am building the 5.3L to have a decent amount of torque off boost. I will still be at 9.5-10 compression ratio, so it won't be a complete dog off boost.

When rao built his car with the LS2, he had a weight comparison. I don't remember the exact numbers, but the S62 is a HEAVY PIG. I can do some research and see what the weight difference will really be, but it doesn't matter to me at all. I can't drive anyway. This car isn't built for anything other than to have fun making a lot of smoke. It will be slammed (not stanced) and have a ridiculously heavy stereo in it. I am just building it for fun. Nothing more.
 
#43 ·
I

The M5 - Sterling Gray, Executive Caramel Leather interior. (Thanks to Clemster for the hook up)

.
I guess it takes a twin turbo LS1 to equal 1 TIMMAY power, although I am not sure the new propulsion unit will be that might lighter...... :devil

Regards,
Jerry
 
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#49 ·
Hmmm looks like a blown head gasket. :grin

Tim I remember your stereo thread, used it for my build. Are you going to do all that work again????!!!!!!
LOL. Blown head gasket. That's probably accurate if anyone knows me......

Yup. Another monster stereo.

iPad as an interface (special software from Alpine)
Alpine UTE-62BT HU
4 way front stage - HAT L1pro (factory location) / HAT L3 (A pillar) / HAT L6 (dash mounted) / Illusion Audio 8" (doors)
Alpine type R rear fill

Haven't decided on the subs yet. I will definitely use Alpine amps and the H800 again. I am slowly acquiring the equipment.

Dash is already out for the L6 install. Adam sold me the car with a vinyl dash. He also sold me a full Caramel Leather interior. So I will use the vinyl dash as my test run for installing the L6 speakers, then transfer it to the leather dash.

 
#51 · (Edited)
I had HAT 8.5" woofers in the other M5. The door card needs modified, but it's not horrible. The baffles for this M5 are a Herrubermensch creation. I acquired them from him.

The exterior color was not my first choice, but it is growing on me. I always wanted a caramel interior though. I haven't decided if I am going to go with the classic, sophisticated styling of the E39 M5 and keep it relatively sleeperish' or if I want to go full r3tard and DTM the hell out of it..... even though I have ZERO plans on racing it. LOL.

 
#53 ·
This is definitely one of the more interesting threads goign on here, though I'll always be a fan of the original M CINCO, that was a beast of a car! I always wondered for a full engine swap like this, when you register the car, do you use the chassis vin or the new engine/ecu vin?
 
#55 ·
great work and craftsmanship, just have a question regarding one of the original pics, you retained the single rail timing chain? (From what I saw it was the bicycle chain type instead of the sandwiched together waffle style type, but you sure about it being able to handle that much horsepower for prolonged periods of time? Keep us posted long term please)
 
#56 ·
To my understanding, based on my research on LS1tech, and advice from rao, it's fine. I'm already way ahead of the game by rebuilding the engine from the ground up. Most guys pull these engines out of the donor, blow the dust off, slap on turbos, and go. Everything on my engine is new......
 
#58 ·
Thanks for your reply Timmay and my concern was with the timing set itself. I rebuilt a Ford 460 many years ago and found the original timing set, (which failed causing me to tear into the motor and since I was already there I figured why not rebuild the whole thing), my OEM set looked like five stamped pieces of metal sandwiched together to form links which made up the timing chain. I replaced it with what looked to be two bicycle chains next to one another which I believe was called a double roller set up. I ended up giving the truck to my buddy and it still hasn't failed. (Truck is an '83 F250, think I gave it to him in 2000). So thanks for the trip down memory lane and what I was thinking with all that extra HP and Torque maybe the timing set isn't stout enough, perhaps I am wrong and the metallurgists have come a long way. Don't know, just wondering
 
#61 · (Edited)
I guess the craftsmanship of my log manifolds is a point of concern, from reading another thread. I guess my welds aren't up to snuff, even though some people can't even weld their own work, they still look to bash other people's work. LOL. Oh well. They are smooth on the inside (purged and smoothed with a die grinder) and will be covered with heat wrap, so I was not very concerned with making them pretty, just strong. I will still bead blast them just to clean them up and check for cracks, but I am not worried at all about what they actually look like........

/rant.
 
#62 ·
People can always figure out something to complain about. Its sad that the first reaction by so many is hate and anger, it's rough going thorugh life like that. Instead of "Wow, cool manifolds" it's "Man, those welds suck, I think I'm going to lock myself in the bathroom and cut myself"
 
#69 ·
Regarding the wastegate placement - did you consult the entropy-enthalpy chart when calculating heat rejection vs angle of placement on the elbow? Also, what role does the chemical makeup/metallurgy of the casting play in thermal expansion against the tension of the clamp?
 
#74 ·
Update:

Reworked the wastegate pieces. They were just too close to the intake housing. I also finished the hot side, mounted the brake controller, and with help from rao, figured out how to easily run all of the brake lines.

Brake controller hidden behind the radiator support under the passenger headlight.








 
#77 ·
Wow, hats off to you Tim. Amazing build so far. Subscribed!
 
#80 ·
Nice progress! Can't wait to see it soon!
 
#89 ·
Back on track:

I have decided to use ceramic coating on the manifolds instead of heat wrap, so I needed to clean up the welds and overall condition of the manifolds since they will be seen after all. I took them to my buddy Karl, who is a REAL welder and fabricator. He did an amazing job. Once sand blasted and powder coated, these should look fantastic.









 
#94 · (Edited)
The lack of "engineering" or any sort of design process shown in this build is astonishing, something one might expect from some sort of domestic "shade tree" contraption but not in a BMW or other suitable performance vehicle. I don't see how one could lead the performance lifestyle in such a "vehicle". I doubt it will ever actually be operable.

As for the commentary, that is just as bad. From the lack of thought to disorganized attempts at "criticism" it is a sad commentary in and of itself.

I refuse to be involved with such a mess.

PS - Swaincoat is really great stuff.
 
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