My Calypsorot 540/6 Thread

[93FIM5]

Awesome video man, car looks amazing! Can’t wait to see more.

-Greg


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[uscharalph]

When you went from the stock bumper to the MTech, what is the solution for the alternator air vent (In the driver's tow hook cover) / alternator air duct? I just created a new post today on this subject. Sorry if you answered this in this post. I've flipped though it a couple of time, but didn't see what I'm asking here. Very nice build!!!

[UnrulyGrace]

I just have this feeling my car is faster

[UnrulyGrace]

Awesome video man, car looks amazing! Can’t wait to see more.

-Greg


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Thanks Greg! I appreciate all of your help up to this point, and looking forward to working with you more in the near future!

[UnrulyGrace]

M60B44 Swap by Jason Grace, on Flickr

Eventful last 5 days!

Picked up BleedsBlue from the airport Thursday morning, and after properly caffeinating ourselves we got to work. Disconnected the battery at 260,853 miles and started disassembly to get the engine and transmission out.

M60B44 Swap by Jason Grace, on Flickr

A throughout degreasing and cleaning was needed since the trans was leaking from the input shaft seal and the shifter rod seal. I can't believe how satisfying it was to get 23 years worth of grime out of the engine bay! By the end of day 1 we had everything out and cleaned.

M60B44 Swap by Jason Grace, on Flickr

M60B44 Swap by Jason Grace, on Flickr

M60B44 Swap by Jason Grace, on Flickr

M60B44 Swap by Jason Grace, on Flickr

M60B44 Swap by Jason Grace, on Flickr

Day 2 lacked in pictures, but it was spent swapping over necessary brackets and other items to the new engine, wrapping the exhaust, torquing accessories down including a new Bosch alternator, a reman Bosch starter, new metal impeller water pump, aluminum thermostat housing, 85* thermostat, velocity stack intake manifold, a bored and polished throttle body, beautifully powder coated valve covers, etc. BleedsBlue installed a new(er) axle shaft on the passenger side as well. Most importantly, we had the new engine in by the end of the day.

M60B44 Swap by Jason Grace, on Flickr

M60B44 Swap by Jason Grace, on Flickr

Day 3 we installed the SPEC lightweight flywheel and Stage 3+ clutch, new slave cylinder, braided line, Garagistic rear shifter arm bracket w/ poly bushing to start. I installed a new shifter rod seal and input shaft seal, along with a new clutch fork, spring, and throwout bearing before getting the transmission bolted back up to the engine. Only issue we ran into was the larger front sway bar was barely in the way, but we easily overcame that obstacle. We reinstalled the driveshaft, heat shield, exhaust, and got the car back on the ground for some fun custom stuff.

M60B44 Swap by Jason Grace, on Flickr

M60B44 Swap by Jason Grace, on Flickr

Little back story - Last time out at the track I noticed power steering fluid was getting hot enough to boil over and out of the reservoir, and ever since I've been wanting to find a better cooling option. Knowing I was getting close to this swap, I purchased a finned cooler that would basically fit where the stock cooling pipe is located. After mock up we ran new soft lines (eliminating a known leak point) and bolted the new cooler in place. Loving the look and the functionality so far, but only time and another track day will tell. That wrapped up day 3.

M60B44 Swap by Jason Grace, on Flickr

Day 4 started by installing the DUDMD M60B44 chip into a 404 DME and cutting pin 66. We played a waiting game for most of the day waiting on serpentine belts to arrive. We were testing different length belts for the under drive pulleys. During the down time, I cleaned a bit more, installed new hood shocks, double checked all of our work, etc. Ended up using a 1580mm belt (stock size in the US) but with the auto tensioner setup it was still a perfect fit. Once we had the belt on we reinstalled the radiator and e-fan, and finished filling with all the fluids. MOMENT OF TRUTH!! To be honest, I was so nervous and anxious I felt like I was having a mini heart attack. After what felt like an eternity the car finally started, but something was off. I was hunting for idle, check engine light was on, and I felt defeated. To top it off, BleedsBlue had to catch his flight home, and I was on my own. Thankfully, I had access to an AutoLogic, so I scanned the car and the only fault was for the crankshaft sensor. I still had the original off my old engine, so I swapped sensors, started the car and it was beautiful! Just an exhaust leak from not tightening the exhaust to the manifolds enough, and a small oil leak from the cam position sensor, but that was it! SUCCESS!

M60B44 Swap by Jason Grace, on Flickr

M60B44 Swap by Jason Grace, on Flickr

Final Checklist by Jason Grace, on Flickr

Huge thank you to BleedsBlue for the helping hands and comradery, Orange County Motorwerks for the shop space, tools, lift, help (couldn't have done this without you), Angry Ass Solutions for the partnership and R&D opportunity, and Motorsports Fluid for the oil, trans fluid.

Excited to get the clutch broken in and get a good 404 DME so I can get the proper tune into the car. Lastly, should have the front bumper and nose panel back from paint today! Videos and more to follow.

[marshallnoise]

Hells yeah.

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[q20v]

Just watched the Home Grown video, awesome! Car looks amazing. I love seeing engine swaps and know the feeling of a first start up. Keep up the good work, very inspiring.

[Flash799]

very nice work and exellent car !
t-shirt outside eh?
greetings from a cold northen sweden -27 celcius (-16 F)

[uscharalph]

I ended up taking my front bumper off to make the procedure a bit easier, and while I had the bumper off I finally figured out where this plastic support went. Seems to add much needed support where needed most on these M-Sport bumpers. With the bumper off, I also trimmed the bottom clips on the fog light delete panels for a better fit.

BMW 51112230372 by Jason Grace, on Flickr

E34 Headlight Reseal by Jason Grace, on Flickr

E34 Headlight Reseal by Jason Grace, on Flickr

I took your suggestion and ordered the plastic support 51112230372.

Do you have / utilize the air ducts for the brakes?

[UnrulyGrace]

I ended up taking my front bumper off to make the procedure a bit easier, and while I had the bumper off I finally figured out where this plastic support went. Seems to add much needed support where needed most on these M-Sport bumpers. With the bumper off, I also trimmed the bottom clips on the fog light delete panels for a better fit.

BMW 51112230372 by Jason Grace, on Flickr

E34 Headlight Reseal by Jason Grace, on Flickr

E34 Headlight Reseal by Jason Grace, on Flickr

I took your suggestion and ordered the plastic support 51112230372.

Do you have / utilize the air ducts for the brakes?

I wish I did, but the ducts are NLA and I’m having one hell of a time sourcing them. After running the plastic support for about a year, my bumper is off being repaired and repainted and I will NOT be reinstalling the support piece. I think it did more harm than good.

[UnrulyGrace]

M60B44 by Jason Grace, on Flickr

[UnrulyGrace]

Bumper and nose panel fresh out of paint

Fresh Paint by Jason Grace, on Flickr

Fresh Paint by Jason Grace, on Flickr

Fresh Paint by Jason Grace, on Flickr

[UnrulyGrace]

Little update since the engine swap, I have a just about 1,500 miles on the new motor, and I have taken care of a few things recently.

-Installed a working 404 DME w/ DUDMD M60B44 chip
-Resealed the passenger upper timing cover since I had a small oil leak that was bugging the hell out of me
-First oil service at just over 1,000 miles
-Replaced a ruptured oil cooler line, and while we were in there replaced the other line as well
-Not even 2 days later my ignition housing broke, and we replaced that and the ignition lock ring
-Installed the clamp that protects the upper radiator hose from touching the oil filter housing (such a nice touch)

IMG_1443 by Jason Grace, on Flickr

IMG_1443 by Jason Grace, on Flickr

IMG_1443 by Jason Grace, on Flickr

IMG_1443 by Jason Grace, on Flickr

Before:
IMG_1443 by Jason Grace, on Flickr

After:
IMG_1443 by Jason Grace, on Flickr

The new engine runs so well, but I really want to install the Maxxecu and have it tuned. I feel like there is a lot left with a proper tune.

[E34 Estate]

Nice and clean, looks great and the choice of steering wheel is superb!!

[BleedsBlue]

Operation bulletproof

So you think that orig 404 was bad?

[UnrulyGrace]

Operation bulletproof

So you think that orig 404 was bad?

i think it was bad, but didn’t verify. You need to get back out here and take her for a spin!

[BleedsBlue]

i think it was bad, but didn’t verify. You need to get back out here and take her for a spin!

No doubt- by the time I do, you'll be totally bulletproof and ready for FI and other shenanigans

[struka]

might want to paint the oil cooler L-bracket black so doenst stick out.

[BleedsBlue]

^He plans to anodize it for sure

[uscharalph]

What are your plans for the old engine?

[UnrulyGrace]

What are your plans for the old engine?

Already sold it to another 540/6 owner. Going to get his car running like it should.

[BleedsBlue]

Already sold it to another 540/6 owner. Going to get his car running like it should.

Oh nice, I was wondering! That thing was strong.

[GazM3]

So how does the new engine 4.4ltr go?

[UnrulyGrace]

So how does the new engine 4.4ltr go?

It pulls hard, but I really want to get it on a dyno and tuned properly. I think there is a lot of potential yet to be unlocked.

[irfaana08]

Great Work!!! Keep up the rad build!