I figured I should start an official build thread. My E39 is a 2000 528i that popped the head gasket at 190K. The car has the sport package which is nice because I like the shadowline look much better. Needs the front bumper replaced and the rear one refinished so M5 repro's are in its future. The GM drivetrain will be a Iron 6.0L LS2/LS3 hybrid using a harness I built and a 4l80E running the TCI / FAST EZ-TCU. I will be using Jesus Freak mounts, Autocraft or Mast oil pan, 2010 Camaro Manifolds (modified) and as much of the 2010 Camaro cats / catback as possible. Going to run the BMW diff initially but will eventually go with a Ford 8.8 w/ 3.73's. This build will take some time but should be worth it in the end.
EDIT: Photobucket sucks and decided to retroactively extort $400 in order to continue 3rd party hosting so these pics are now reposted through BimmerForums (thanks BF!). BimmerForums only allows for 5 pics per post so the photos bounce around a bit but the content is all there. Just click on the small pictures and they will open up larger in another window.
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- - - Updated - - -
Today's Project is the Radiator. I bought a aluminum radiator from Speedway Motors designed for 60's Chevy cars and began modifying it for E39 duty. The water necks are in the correct position but I needed to remove the filler neck and add mounting brackets. This generic radiator has overall measurement that are very close to Behr unit so I am trying to mimic the original mounting design. Got the mounting brackets done but ran out of Argon before I could remove the filler neck and patch the hole. Reminded myself that I am still lousy at TIG welding aluminum, give me mild or stainless steel any day...
See post #4 for balance of pics.
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Last edited by StolenFox; 07-03-2017 at 08:57 PM.
Todays project: Prepare the engine and car for the 4L80E. Swapped the T56 flywheel for appropriate flexplate and "persuaded" the trans tunnel to accept this monster.
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Last edited by StolenFox; 07-01-2017 at 04:58 PM.
Did you check to see where the trans wiring plug lands? I had to cut a little section out of the unibody rail so mine doesn't hit. It's still a tight fit. Almost have to drop the crossmember to plug the harness in. Keep up the good work!
Last edited by unnatrl; 05-30-2016 at 07:30 PM.
Pic overflow from Post #1
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I'm trying to avoid cutting and welding the tunnel if I can so I am going off measurements right now. The connector and trans pan rail are 14-7/8" wide which is the widest low point on the trans. The connector is approx 9" forward of the transmission mount pad. The "Jesus Freak" mounts I'll be using center the GM trans mount with the rear mounting bosses on the E39 so I could mark the 9" reference on the unibody. At those reference marks I've got it opened up to about 15-1/4". I expect it to be tight and plan on having to lower the trans if it ever has to be unplugged. The idea was that this (provided it is enough) will allow me to fit the 4L80 without loosing the tunnel strength that the unibody doubler stamping provides. Hopefully it's enough room but if not, no worries I will just cut out the outer wall doubler.
Thanks for the encouragement!
S.F.
Last edited by StolenFox; 07-02-2017 at 10:14 AM.
Nice "name" for the project sounds familiar
I like the prefacelift chassis, a classic.
Also great little engine test stand, love the mufflers! Off a 5th Gen I assume?
Oh crap, I hope I didn't steal someone's project name! I should've looked to see if that one was being used..... I agree on the non-facelift, I like the black contrast on the white of the door rub strips vs all monotone. Haven't studied the heads and tails to see which version looks better.
Thank you for the kind words on the run stand, it works awesome. Kind of cool to twist the key and light it off just like a car..... but different. Good eyes on the mufflers, they are indeed off a gen 5. Got the whole cat back for $20.00
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Today's update: Got the "Jesus Freak" mounts and the Mast Motorsports oil pan bolted to the mock up engine / 4L80E and toss it all into the car to check clearances. I know everyone who has the I-6 sub frame is using the Autokraft / Champ pan but I wanted an aluminum pan that functions as stressed member. The folks at Mast were kind enough to offer a damaged oil pan for me to use for mock-up testing on the LSx E39. I thought that was amazing service considering it may not have resulted in a sale! Anyhow, I am happy to report that the we now have the option to run a aluminum pan on our conversions as The Mast pan fits very well. Plenty of clearance (1/4" plus) for front of the sump by the sub frame cross brace and close but acceptable clearance (1/8") at the ridges across the steering rack. I did adjust the upper hard line on the rack for a little more sump clearance but that was very easy and quick to do. I will file down those ridges on the rack just a bit in order to get a little more clearance but its only for peace of mind and not really necessary. I intentionally did this testing with the 190K worn out isolators that have compressed over time so I could check the clearances in the "worst case scenario". Rack clearance should only improve with new isolators. A big thank you to Josh for the beautifully constructed mounts. I am thoroughly impressed at the engineering and quality that went into them. Another big thank you to Russ @ Mast for generously loaning me a pan for testing. That is uncommon service these days for sure!
Pics:
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See Post #12 for balance of pics
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Last edited by StolenFox; 07-01-2017 at 04:59 PM.
Last edited by StolenFox; 07-01-2017 at 05:00 PM.
Today's project:
I built a holder for my 4L80E in anticipation of rebuilding it. Also shaved the ridges down on the rack and hit them with zinc rich coating.
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See Post #14 for overflow pic.
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Last edited by StolenFox; 07-01-2017 at 05:01 PM.
Neat project...you have quite the skillset!
Note to self: Must Learn To Weld.
Tipsy
Overflow pics from Post #7
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Overflow pic from post #8
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Very kind of you to say. Nothing compared to many that fabricate professionally and/or frequent these boards. The thing with me is I guess i'm just brave (or stupid) enough to try...
I'm self taught and would love to someday take a welding course so I could improve. I do pretty well with Mig, Tig & Stick on mild or SS. I can Tig weld aluminum just well enough to get by, not "stack of dimes" pretty but it does the job. I think i would benefit from a TIG machine that has all the waveform adjustments as my machine is an "Old School" Miller Econo-Tig and the only adjustment is AC/DC electrode (+) or (-) and amperage.
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Last edited by StolenFox; 07-02-2017 at 10:15 AM.
Clearance on the pan looks good. Just about like the autocraft. Nice work all the way around! I also need to learn how to weld.
Overflow pic from post #9
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Started tearing down the transmission today. What have I gotten myself into?
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Also unhooked everything from the engine so I can get it pulled off the run stand.
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Last edited by StolenFox; 07-02-2017 at 10:17 AM.
Today I put the engine in the bay. Needed to make room in the garage for the 4L80E rebuild so the engine had to come off the run stand and the stand needs to go to into storage.
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Last edited by StolenFox; 07-02-2017 at 09:07 AM.
I built the PCM and fuse block mounts:
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You guys with the Gen 4 (E38 & E67) pcm's got it made with those tiny computers, this Gen 3 is huge!
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Last edited by StolenFox; 07-02-2017 at 09:13 AM.
I'm still slowly rebuilding the transmission (keep finding damaged hard parts) but snuck in a couple other projects. I'm using 2010 Camaro SS manifolds and the drivers side dumps right into the steering shaft. To fix that problem I cut off the dogleg collector and made a new straight one out of 304 stainless. Still got to get the collector angle figured out then final weld it all.
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Then, a major score in the form of 2010 Camaro Front Engine Accesories. Helped a friend on his 67 Pro-touring Camaro and received the accesories as thanks. The iron LS blocks are not drilled and tapped for the alternator mount so I made a drilling jig and got to work. Also ordered the water pump to complete the set.
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Last edited by StolenFox; 07-02-2017 at 09:20 AM.
I've been curious if the LS3 Camaro manifolds would fit. I dig the mod on the manifold. Looks like it will emulate the Holley LS swap manifolds when it's done. Probably a whole lot cheaper too!
yeehaw! keep it coming.
Last edited by StolenFox; 07-02-2017 at 09:25 AM.
DSC pump relocation and radiator bracket rough in:
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Last edited by StolenFox; 07-02-2017 at 09:28 AM.
Just found this. Looks great.
E90 335i
On3 Performance top mount single turbo kit, Precision 6466 Turbo, ECS Tuning charge pipe, 7in FMIC, JB4 w/ MHD backend flash, Stage 3 fuel pump, Port injection, E85, some wheels that came w the car but are thick
E39 540i (SOLD)
6 spd swap, "Almost Nardo" Vinyl Wrap, JB Racing LTW flywheel, M5 clutch & control, BC Racingcoilovers, cat back straight pipe, E60 SSK, ZHP shift knob, hard wired aux, Style 32 17", BFG G-force Sport Comp-2 tires, shadow-line trim, reenforced differential bushing, ATE Type 200, Hawk HP Plus pads, intake res delete, 10W40 M1, trans fill 50/50 Redline MT-90 & 75w90NS, solid shifter carrier bushing, pixel fix, red needles
Well, I decided against using a pressurized plastic reservoir because its seems like they all fail and I couldn't find one that fit where I wanted to put it. So, It was time to build a new filler neck assembly and weld it on the radiator. Came out pretty good and there is plenty of hood clearance for the cap. Transmission rebuild is ongoing but getting closer. The goal is to be able to fire the engine in the car before winter. Once the snow is falling, I'm pretty much done in my non-insulated garage.
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Last edited by StolenFox; 07-02-2017 at 09:34 AM.
That filler looks awesome.
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