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

  1. #101
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    Quote Originally Posted by JimLev View Post
    Nice work as usual Schitzo.
    If you get sick of MN, there is a house right across the street from me that is for sale.
    Just think of all the trouble we could get in.
    I'll be heading down to the Cape once again this fall. Maybe I can drive down there this time and swing by. That would be an awesome drive!

    2003 M5 LSx l 6 Spd Manual l 4.10 LSD
    Build Thread
    The chassis must always be regarded as a means to an end and never as an end itself

  2. #102
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    This is very interesting information, since I am currently in the position of buying a new band saw and making a table setup for it (I'll by a cheap horizontal 4x6 from Harbor Freight and then get a good blade for it), or buying a low-end semi-cold saw. I'm curious why the cold saw is easier to get your proper angles with?

    On a related note, check out this video at about 1:47. The guy is using a proprietary cutting jig from icengineworks, but the whole thing could be pretty easily fabbed up out of some wood scraps for a low volume non-professional operation. I think this plus the right little table for a low-end band saw, or even your portaband setup, might make for a nice little fabrication rig:

    https://www.youtube.com/watch?t=107&v=R1THlAZ2BqI

    Quote Originally Posted by Schitzo View Post
    It's a semi-cold cut saw; no coolant but uses a carbide tipped blade.
    This is the band saw and table I use.

    It works great most of the time but it's a little more challenging to achieve what I want when cutting exhaust tubing. In order to ensure a perfect fit at the cut joint, I must cut it at 90 degrees to the tangent of the bend (or to the centerline for a straight section of tubing). Achieving this with the band saw is what is proving difficult and time consuming. With the chop saw, I can have a cut done in under a minute; the band saw takes up to 3 minutes. Mostly because I'm cutting slowly for the sake of accuracy.

  3. #103
    JimLev's Avatar
    JimLev is offline Artifically Aspirated Moderator
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    Quote Originally Posted by Schitzo View Post
    I'll be heading down to the Cape once again this fall. Maybe I can drive down there this time and swing by. That would be an awesome drive!
    Sounds good, let me know as much in advance as you can. I could also meet you 1/2 way too.

    Nice info in that video tptrsn.

  4. #104
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    That looks like the Ice engine Works cutting jig.

    Trying to get perfectly aligned cuts in stainless is a noble goal, but unless you are prepared to waste a huge amount of tubing you might want to consider learning to accept something less than perfection and learn how to TIG weld gaps
    Rob
    Prior projects:
    1998 540i with 6.6 LS2/T56 Chevy Power
    - pictures and details
    1992 325i with 6.6 LS2/T56 Chevy power - pictures and details
    1995 M3 with 6.6 LS2/T56 Chevy power - pictures and details




  5. #105
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    Quote Originally Posted by tptrsn View Post
    TI'm curious why the cold saw is easier to get your proper angles with?
    The tube is clamped down securely when on the chop saw. On the band saw, I'm holding the tube with both hands and eye balling the cut/angle; I follow a scribe line on the tube.
    Quote Originally Posted by JimLev View Post
    Sounds good, let me know as much in advance as you can. I could also meet you 1/2 way too.
    Will do.
    Quote Originally Posted by rao View Post
    consider learning to accept something less than perfection and learn how to TIG weld gaps
    Unseemly

    2003 M5 LSx l 6 Spd Manual l 4.10 LSD
    Build Thread
    The chassis must always be regarded as a means to an end and never as an end itself

  6. #106
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    Nice update Robert. Looking forward to more.

  7. #107
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    Quote Originally Posted by Schitzo View Post

    Unseemly
    Rob
    Prior projects:
    1998 540i with 6.6 LS2/T56 Chevy Power
    - pictures and details
    1992 325i with 6.6 LS2/T56 Chevy power - pictures and details
    1995 M3 with 6.6 LS2/T56 Chevy power - pictures and details




  8. #108
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    Thanks Schitzo!

    Just wondering since you have used both, for someone like me who is willing to TIG fill gaps in an imperfect fitup, would you recommend a band saw or $400 range cold saw for ease of use and minimum frustration when trying to just get the job done and have it be functional?

  9. #109
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    Quote Originally Posted by tptrsn View Post
    Thanks Schitzo!

    Just wondering since you have used both, for someone like me who is willing to TIG fill gaps in an imperfect fitup, would you recommend a band saw or $400 range cold saw for ease of use and minimum frustration when trying to just get the job done and have it be functional?
    I assume you will be cutting more than just the exhaust tubing so go for the bandsaw; it's the more versatile of the two.

    2003 M5 LSx l 6 Spd Manual l 4.10 LSD
    Build Thread
    The chassis must always be regarded as a means to an end and never as an end itself

  10. #110
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    Alright thanks, I appreciate the insight!

  11. #111
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    looking forward to this build. Show us pics of the new workspace.

  12. #112
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    Cam came in this morning. I now have everything needed to start assembling the engine. Well, everything except an engine stand. My HF stand which I purchased back in '05, and have barely used, had a cracked weld on the main support beam; I almost dropped the block on my feet trying to fit it on the stand. Rather than repair it, I sent it to the scrap yard. Having spent the weekend shopping for a replacement stand, I might be better off just building one myself though I'd prefer not to. Any suggestions for a good engine stand?



    Finished a few other projects around the car including cutting holes on the shroud for the fans and removing tint from the windows. The car came with very dark tint which I didn't care for and I'm sure MN's finest wouldn't care for it either. I used a clothes steamer that made the job rather painless (not including a few burns here an there from the steam. Not sure why I wasn't wearing gloves! )

    Quote Originally Posted by mapleridge View Post
    looking forward to this build. Show us pics of the new workspace.
    It's your typical 3 stall garage with two stalls being extra deep. The workbench is the same one I had at the old garage.

    http://i412.photobucket.com/albums/p...ouse/bench.jpg
    http://i412.photobucket.com/albums/p...House%2019.jpg
    http://i412.photobucket.com/albums/p...use/garage.jpg

    2003 M5 LSx l 6 Spd Manual l 4.10 LSD
    Build Thread
    The chassis must always be regarded as a means to an end and never as an end itself

  13. #113
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    looks like a fine workplace. May it be a place of joy and many great builds.

  14. #114
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    That is a nice place. Grats.

  15. #115
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    why not just buy another HF stand and work some gusset and reinforcement magic on it? wouldn't take more than a night with the cutoff wheel and welder to add some reinforcements. Mine is still going strong after a few years right as it came out of the box. Maybe yours was built on a Friday in China that day.

    new place looks fantastic, love the 3 car.
    Last edited by nsogiba; 05-20-2015 at 09:12 AM.

    2001 BMW 560i 6.0 LSx/T56 SOLD


    2000 Corvette Hardtop FRC

  16. #116
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    my fully dressed engine has been sitting on an hf engine stand for the better part of two years, rotated and moved around plenty and it hasn't broken yet. for $60 you really can't beat it.....maybe you just got a poorly made one?

    and dear god man, your new place looks incredible. love all the hardwood accents and flooring
    Last edited by ckpitt55; 05-21-2015 at 01:35 PM.

  17. #117
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    Made some progress; will keep this brief; too tired to type much.

    Plans (dual 3". Rear section going to mufflers not shown)


    Created wooden jig to help keep things aligned and flat where needed. Works great!
    x-pipe welded.


    Test fit x-pipe and measure for tubes between the x-pipe and CATs. Tape measure says 12" +/- 2CH.



    Pipes cut, mocked on the jig, and tach welded.


    Final check before welding.


    Purging. 5 cfh argon.


    Welded



    Back on jig; started on the rear section (from x- pipe to rear Vbands).




    2003 M5 LSx l 6 Spd Manual l 4.10 LSD
    Build Thread
    The chassis must always be regarded as a means to an end and never as an end itself

  18. #118
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    Schitzo, impressive exhaust pipe work! you're hired. I need a straight pipe to replace my muffler delete lol.

  19. #119
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    Nice work. Where are you getting the mandrel bent pieces from?
    I've decided it's time I bought a TIG welder and started learning how to use it.
    Looks a bit easier than MIG.

  20. #120
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    great work, digging the fixture

  21. #121
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    stop making the rest of us look bad.

    2001 BMW 560i 6.0 LSx/T56 SOLD


    2000 Corvette Hardtop FRC

  22. #122
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    Jim, I bought the bends from these guys
    https://www.mandrel-bends.com/catalog/
    They ship the tubes with bending oils still on them so be prepared to do some cleaning if you order from them.
    I'm curious. Why do you think TIG is easier than MIG?

    2003 M5 LSx l 6 Spd Manual l 4.10 LSD
    Build Thread
    The chassis must always be regarded as a means to an end and never as an end itself

  23. #123
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    JimLev is offline Artifically Aspirated Moderator
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    Mandrel Bends, I looked at their parts a few days ago, they were one of many.
    Order a few bits from them yesterday.
    I've MIG'ed a bunch of times, never TIG welded before, it just looked easier to do when I watched a few peoples do it.

  24. #124
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    Quote Originally Posted by JimLev View Post
    I've MIG'ed a bunch of times, never TIG welded before, it just looked easier to do when I watched a few peoples do it.
    Rob
    Prior projects:
    1998 540i with 6.6 LS2/T56 Chevy Power
    - pictures and details
    1992 325i with 6.6 LS2/T56 Chevy power - pictures and details
    1995 M3 with 6.6 LS2/T56 Chevy power - pictures and details




  25. #125
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    Once you get the hang of tig welding, I think there are certain jobs that are MUCH easier with a tig than with a mig. Fabbing an exhaust is one of them, at least with my mig... Getting the hang of tig welding is quite a bit more challenging than getting the hang of migging though.

    Would you agree with that assessment Schitzo? BTW, your work on that exhaust is stunning!

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