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Thread: Project 560i: my E39 LSx build

  1. #126
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”

    Interior restoration work!

    So my seats looked like crap and needed to be dyed badly. Leatherique to the rescue!

    A9FB0F31-968F-43C2-A960-0C76099966C4.jpg

    E7E81496-C11F-4AA3-8992-4517A7328E6E.jpg

    C968BDA2-E0E4-42B9-B6A9-2807836AB0AA.jpg

    56194DB6-FCB2-4342-AA57-14DF76BBF5FF.jpg

    More pics to follow.

    S.F.

  2. #127
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”

    More seat work

    IMG_2023.jpg

    IMG_2020.jpg

    IMG_2021.jpg

    IMG_2024.jpg

    It's a ton of work but the results are worth it.

    S.F.

  3. #128
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”

    And in other news:

    Work has begun on the 8.8 conversion. This one is going to take a while as I have to build the rear mount, build the front mount structure and weld it to the spare subframe, rebuild the Diff and then have axles and a driveshaft made.


    93C6040D-62AF-4903-957E-F2B10AEB1201.jpg

    47C57B5D-B587-4A4B-AE75-A894F988D632.jpg

    Also have the 540i front brakes and springs to install.

    S.F.
    Last edited by StolenFox; 05-01-2018 at 07:36 AM.

  4. #129
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”

    Front brake upgrade: 540i spec

    I grabbed a set of calipers off a 2003 540i and rebuilt them with new pistons and seals. Installed them with new Centric “High Carbon” rotors, Hawk HPS pads and StopTech braided stainless lines.

    DCD29E14-6175-407F-BD65-A90A224E23A0.jpg

    725290A6-EDB7-4CF0-A607-8CA8DC36000E.jpg

    Big difference in rotor diameter and thickness from 528i vs 540i:

    815A0DD9-B565-4D5A-8059-45A411E4E938.jpg

    17F140EF-4630-438C-AAA7-EC496F490C96.jpg

    S.F.

  5. #130
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”

    8.8 Diff converstion engineering work begins:

    Latest project is getting the 8.8 differential mounted into the spare subframe:

    1E66D9B5-A6C3-45EE-8527-599C64A08CE9.jpg

    3FE59906-DB6E-4333-B3D9-DDB6A317B3A7.jpg

    CA137037-7444-4E57-9268-A9177A9D68F7.jpg

    83130812-7425-422A-B038-ACC4B21B3842.jpg

    Pics of the Diff mounted in the spare subframe to follow.

    S.F.

  6. #131
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”

    More Diff work:

    I still the need to build the front mount but here's the 8.8 bolted in the spare subframe:

    IMG_2059.jpg

    S.F.

  7. #132
    Join Date
    Nov 2006
    Location
    Minneapolis,MN
    Posts
    2,260
    My Cars
    2003 M5, 2014 535i
    You are making this look too easy!! It took me much longer to get to this point. How did you cut the steel plate? Angle grinder, plasma, torch? Looks to fit within the cover really well.
    PM sent

    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

  8. #133
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”
    Quote Originally Posted by Schitzo View Post
    You are making this look too easy!! It took me much longer to get to this point. How did you cut the steel plate? Angle grinder, plasma, torch? Looks to fit within the cover really well.
    PM sent
    Sir, if I'm making it look easy it is only due to all the information that you have graciously provided! If it wasn't for you, I'd still be looking at the spare sub-frame / 8.8 trying to decide if I really wanted to take on the project....

    As far as cutting the plate: I made a template first out of several layers of painters tape and then transferred it to a file folder which I cut out as a template. I then marked the plate with machinist dye, scribed the pattern, outlined it with soap stone and then free hand cut with a plasma cutter. I've been using plasma cutters for over 20 years so you could say I have had plenty of practice. Slow, methodical torch control with my face right by the cut line (welding hood on of course) made a finished product that fits within 1/16" of the cooling fin perimeter of the casting. I'd love to have access to a CNC plasma table or Plasma-Cam but this method worked really well.

    Thank you again for all your help!
    S.F.

  9. #134
    Join Date
    Nov 2006
    Location
    Minneapolis,MN
    Posts
    2,260
    My Cars
    2003 M5, 2014 535i
    The 20 yrs definitely shows...really tight fit up around those bends. Looking forward to more progress.

    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. #135
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”

    Front diff mounts:

    Began roughing in the front diff mounts yesterday. Going to finish weld, trim to net shape and media blast this week. I already machined the aluminum sleeves to tig weld into the subframe and I’ll use the steel brackets to help locate the drill points.

    i also cut the mounting bosses off the explorer diff cover as “plan B”....

    in in other news: I think I want to switch from 4L80E to TR6060, wonder if anyone over at Camaro5.com wants to trade.

    E412B94B-8750-4A28-9020-584BC2A93B39.jpg

    S.F.
    Last edited by StolenFox; 09-03-2018 at 08:12 PM.

  11. #136
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”

    New shoes!

    Still slowly working on the diff project but wanted to show off the new rolling stock:

    283657EA-AD3F-48E1-9725-8E4C63F774D2.jpg

    81B492E5-35AA-48EB-8BD1-46AE75FB63AE.jpg

    S.F.
    Last edited by StolenFox; 09-03-2018 at 08:09 PM.

  12. #137
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”

    Appropriate badging:

    Old:

    AF125D34-1405-4646-9649-B004D9CB981A.jpg

    As delivered:

    D2C955E5-0F86-4717-9E32-53853E0A9D96.jpg

    Truth in advertising:

    FB526B7A-E16E-4CAF-8E2E-09BF423C32FA.jpg

    Still working on the diff mounts/ 8.8 rebuild but might have just been sidetracked by a TR6060....

    S.F

  13. #138
    Join Date
    Jun 2015
    Location
    Anchorage, Alaska
    Posts
    23
    My Cars
    1997 BMW 540iA
    Nice! I'm probably going to get a "318ti" tag and and make my "540i" into "548t".

    Will you be making a limited run of 8.8 conversion plates? It looks real good!
    Last edited by akinshok; 07-30-2018 at 04:24 PM.

  14. #139
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”
    Quote Originally Posted by akinshok View Post
    Nice! I'm probably going to get a "318ti" tag and and make my "540i" into "548t".

    Will you be making a limited run of 8.8 conversion plates? It looks real good!
    Thank you sir!

    I don't think ill be going into the performance parts (side) business again, not enough time anymore...

    S.F.

  15. #140
    Join Date
    Jun 2018
    Location
    Virginia
    Posts
    44
    My Cars
    2002 BMW 525iT
    Would you be comfortable estimating what the complete 8.8 conversion is going to cost you once complete? Great work!

  16. #141
    Join Date
    Oct 2004
    Location
    DeWitt, Michigan
    Posts
    6,080
    My Cars
    '97 540i/6, '97 328i

  17. #142
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”
    Quote Originally Posted by 67Riviera View Post
    Would you be comfortable estimating what the complete 8.8 conversion is going to cost you once complete? Great work!
    Thank you sir! It's a bit early to accurately get a total cost estimate as I've only bought a junkyard diff and built the mounts so I'm only $100 in so far. I need to rebuild the diff, install a limited slip unit, buy axles and have my driveshaft modified....

    Quote Originally Posted by tptrsn View Post
    The results of your efforts on your seats are incredible!!
    Yes, I was very happy with how the came out. Not 100% perfect but a million times better than they were!

    S.F.
    Last edited by StolenFox; 09-20-2018 at 05:55 AM.

  18. #143
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”

    Latest update:

    Diff mounts & Subframe are finished. Diff still needs to be rebuilt though..:

    F90683B1-7962-4AE5-8B61-6F097CB76631.jpg

    And, I bought a TR6060 that needed a little work off the Camaro5 board:

    16FB0A80-7520-4189-A6E3-F4B19022030A.jpg

    She’s getting:

    hybrid blocker rings on 1,3,4,5 & 6th gears
    Full carbon blocker on 2nd gear
    Bronze shift fork pads
    New 2nd gear and 1-2 synchro
    New 3rd gear and 3-4 synchro

    1D6C5303-C5DA-4307-810A-54547838FA6C.jpg

    S.F.
    Last edited by StolenFox; 09-03-2018 at 09:05 PM.

  19. #144
    Join Date
    Nov 2006
    Location
    Minneapolis,MN
    Posts
    2,260
    My Cars
    2003 M5, 2014 535i
    I like the way the diff mounts turned out; the front mount looks really study.
    Have you decided on what you will do with the driveshaft? perhaps two piece with a slip yoke in the middle or a plunging CV at the diff?

    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

  20. #145
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”
    Quote Originally Posted by Schitzo View Post
    I like the way the diff mounts turned out; the front mount looks really study.
    Have you decided on what you will do with the driveshaft? perhaps two piece with a slip yoke in the middle or a plunging CV at the diff?
    The TR6060 swap is going to make the driveshaft a three phase process:

    Phase 1 will be to swap transmissions only and modify the front section of the existing shaft. Ill be using the Sonnax TR6060 flange to 1350 u-joint adapter and cutting down the front section and install a new weld yoke.

    Phase 2 will be to drive the car a bit and make sure I didn't screwup the TR6060 rebuild.

    Phase 3 will be the installation of the modified subframe and Ford 8.8 (once I get around to rebuilding it) and then come up with a plan for the rear section of the driveshaft. I like the "CV joint at the diff" idea". Perhaps a custom flange for the 8.8 that would accept the BMW CV joint?

    Or ill sell a Kidney and have DSS build me a custom unit with a Camaro CV at the front and a 1350 u-joint at the rear...

    S.F.

  21. #146
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”
    Transmission swap has begun! 4L80E, shifter assembly, shift cable, TCI trans controller and custom switch panel will all be for sale soon.

    S.F.

  22. #147
    Join Date
    Oct 2018
    Location
    Southeastern CT
    Posts
    19
    My Cars
    1997 528i Auto
    Just read your whole thread. Awesome build.

    What did you do with the air intake / filter assemblies for the heat/AC in the engine bay? Could you post a recent, completed engine bay pic?

    Thanks

  23. #148
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”
    Quote Originally Posted by dillont View Post
    Just read your whole thread. Awesome build.

    What did you do with the air intake / filter assemblies for the heat/AC in the engine bay? Could you post a recent, completed engine bay pic?

    Thanks
    Thank you, it’s been a ton of work but worth it. The intake are exactly as they were from the factory, no changes at all!

    S.F.

  24. #149
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”

    6-speed progress:

    TR6060 rebuild is done, trans is in, pedals converted, PCM wiring modified, clutch hydraulics installed and 5th gen Camaro short shifter installed in the modified tunnel.

    6CACB29D-CD82-4CEA-A06E-014390E3A8FB.jpg

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    C6AFCD00-84C3-42F6-8FFC-209C08E0CC34.jpg

    S.F.

  25. #150
    Join Date
    Apr 2012
    Location
    Stuttgart, Germany
    Posts
    577
    My Cars
    1997 M3 / 5.3
    That is quite a bit of detail for just one post! That clutch master reservoir bracket is sick!

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