My New Project: LS/T56 swap into a 2003 E39 M5

[Schitzo]

Thanks Robert, I need one of those! I'll probably shoot over to O'Reilly today and see if they have one. If not I'll order one. Looks handy as heck!

Regarding the pedal "one-ness," on top of cool shoes I think I need a new pedal. The one that came with my welder is wearing me out. These are supposed to be nice:

http://weld.com/index.php/shop-weld-...6-model-detail

Sorry for the off topic! Back to more regularly scheduled e39 weld/fab porn. Lol

Thad, that is the pedal I use (Mine is a 2013 model). It is very well made and has worked great since the day I bought it. Let me know if you have questions on it.

[tptrsn]

That's good enough for me, I'm going to order one -- thanks!! :-)

[modular93fox]

Nice progress!

[Schitzo]

Nice progress!

Ninja edit there
My take has always been use whatever tool works best for you for the job at hand. In this case, either tool would have worked just fine.
Still interested in hearing how the DC motor worked out for ya; you can PM me.

[tptrsn]

This tool has now been added to the "Oh my god I'm sooooo stupid for not owning this until so late in my life!!!" list. Such awesomeness!

[nsogiba]

It's Sunday night. Do you know where your updates are?

[JimLev]

It's Sunday night. Do you know where your updates are?

Mine are still up on 4 jackstands.
Nice pounder to get the round back.

[Schitzo]

It's Sunday night. Do you know where your updates are?

Right here

I didn't get to work on the car last weekend as we had family staying with us for Easter but this weekend was open so I was able to make good progress.
Once I had fabricated the collectors, as noted on my last update, I needed join them together and position them under the car. This would make it much easier to finish working on the primary tubes. In order to mount the collectors on the car, I used the same stand I used to hold the muffler tips; I just tweaked it a little bit to work with the collectors.



I was then able to place this set up underneath the car and position the collectors exactly where I wanted them.



From there, I started extending the primary tubes. This time I started with the tube for cylinder #4 followed by cylinder #2. I did it in this order since these two tubes run closest to the starter and transmission bellhousing. I needed to make sure I was leaving ample room between the header tubes and starter + bellhousing..
Here I have completed #4 and #2. I only had them in and out of the car about a million times. The other times I was searching for my sharpie which I manage to misplace every single time I use it . Anyway, I digress. Note the ground clearance; the header sits above the lowest section of frame rail which is exactly what I was shooting for.



Having done, #2 and #4, I can now start working on tube #6 and #8. Since I know their positions relative to tube #2 and #4 and relative to the the collector, I can fab these tubes off of the car which should make it much easier.

Setup off the car. I just need to add a support for the header flange then I can start extending #6 and #8.

[nsogiba]

are you running a 6 cylinder front subframe in this car?

[Schitzo]

are you running a 6 cylinder front subframe in this car?

Yep. See post #3 for the reasons I used the I6 subframe.

[tptrsn]

It always freaks me out too when I see it (I6 subframe). Lol

BEAUTIFUL work as always, BTW. And knowing how much all of those slip fits, stainless tubing, and everything else costs, this is going to be an expensive set of headers. Still, pretty economical compared to SuperSprint or something I expect. Glad you're cranking out work!

[Schitzo]

It always freaks me out too when I see it (I6 subframe). Lol

How so?

BEAUTIFUL work as always, BTW. And knowing how much all of those slip fits, stainless tubing, and everything else costs, this is going to be an expensive set of headers. Still, pretty economical compared to SuperSprint or something I expect. Glad you're cranking out work!

Believe it or not, it is not as expensive as you would think espceially considering I don't incur labor costs. When done, as you said, it will still be cheaper than your average BMW SS V8 header. I couldn't imagine paying someone to build this same header for me. It just wouldn't make sense; to me, that is.

[tptrsn]

I'm just used to seeing the V8 subframe of the 540 under there.

Those headers are going to be amazing!

[Schitzo]

Sunday night update

Work continues on the passenger side header. I managed to fabricate tube 8 and 6. I have to say this was the most difficult and time consuming part of this header build mostly because any changes to one tube would affect the other three tubes so I needed to make many changes as I went. In any case, all the tubes are now exactly how I want them (well......except for that goofy joint on tube #2; I may redo it). The only thing left to do is to fully weld all the tubes.

Jig plus all the primary header tubes


ready for final welding.

[tptrsn]

Bravo Maestro, another piece of fine art!!

Looking at that makes me feel like the hack that I am. Lol

[JimLev]

You do excellent work. A master craftsman at work.

[nsogiba]

The alignment marks where the primaries meet the flange show how much pain you went through. Hope you're all stocked up on gas!

[Schitzo]

The alignment marks where the primaries meet the flange show how much pain you went through.

Agreed. I am sure the driver side header will be much more fun!!

A while back you had asked about exhaust fab so I figured I would share this video of a build I have been following. They fabricate the exhaust starting at the 12:58 minute mark. Awesome fab work plus some good English humor.
https://www.youtube.com/watch?v=NMT9...tu.be&t=12m58s

[JimLev]

I like the part where they cut a 90° part in 3 pieces, flip the center section and weld it back together to gain clearance.
That subframe was pretty rusty.

[M5Hunter]

Looking great!

[auaq]

How much do ya charge for TIG classes?

[modular93fox]

Agreed. I am sure the driver side header will be much more fun!!
A while back you had asked about exhaust fab so I figured I would share this video of a build I have been following. They fabricate the exhaust starting at the 12:58 minute mark. Awesome fab work plus some good English humor.
https://www.youtube.com/watch?v=NMT9...tu.be&t=12m58s

Do you think fusion welds are strong enough for exhaust? That's what his looked like when he was welding.

[Schitzo]

I like the part where they cut a 90° part in 3 pieces, flip the center section and weld it back together to gain clearance.
That subframe was pretty rusty.

Right. Great technique for an offset bend. I also liked the jig they made for cutting the tubing.
Any update on your exhaust or has it taken a back seat to moving?

Looking great!

Thanks Clay

How much do ya charge for TIG classes?

Beer is my currency but this guy offers TIG tips for free.
https://www.youtube.com/user/weldingtipsandtricks

Do you think fusion welds are strong enough for exhaust? That's what his looked like when he was welding.

They can be just as strong as welds made with filler but are more prone to failure if done incorrectly. Most tubing used for exhaust is made from flat sheet that is rolled into a tube then fusion welded at the seam.



I made some progress this weekend but didn't get to post it last night. I will have an update this evening.

[JimLev]

[QUOTE=Schitzo;29199736]Right. Great technique for an offset bend. I also liked the jig they made for cutting the tubing.
Any update on your exhaust or has it taken a back seat to moving?


QUOTE]

Haven't touched it in 3 weeks, too busy getting the house ready for sale.
The real estate photographers are coming today. It lists later this week.

[auaq]

That channel is a great channel on YT for learning Mig/Tig welding and other cool tricks.