Page 1 of 8 12345678 LastLast
Results 1 to 25 of 177

Thread: Project 560i: my E39 LSx build

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

    Project 560i: my E39 LSx build

    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.

    S.F.


    image_1.jpg

    image_3.jpg

    image_2.jpg

    IMG_0574_1.jpg

    IMG_0547.jpg


    S.F.

    - - - 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.



    S.F.
    Last edited by StolenFox; 07-03-2017 at 08:57 PM.

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

    622320C5-3DFB-4A19-9DC7-A64DC4D45CCE.jpg

    4BDB9A98-AA32-49EC-B2BF-0EF487CFDE2E.jpg

    E1DAFC20-ED0D-4643-8C4A-B8830D467C9E.jpg

    39C6ECE4-7A15-40FE-A84F-A601B0B3A78B.jpg

    S.F.
    Last edited by StolenFox; 07-01-2017 at 04:58 PM.

  3. #3
    Join Date
    Oct 2008
    Location
    West coast
    Posts
    1,316
    My Cars
    '00 540 6.0/4L80e/S480
    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.

  4. #4
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”
    Pic overflow from Post #1
    image.jpg

    IMG_0997.jpg

    IMG_1002.jpg

    IMG_1004.jpg

    IMG_1005.jpg

    Quote Originally Posted by unnatrl View Post
    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!
    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.

  5. #5
    Join Date
    Jun 2011
    Location
    Buffalo, NY
    Posts
    1,703
    My Cars
    2001 BMW 540i/6
    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?

    2001 BMW 560i 6.0 LSx/T56 SOLD


    2000 Corvette Hardtop FRC

  6. #6
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”
    Quote Originally Posted by nsogiba View Post
    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

    S.F.

  7. #7
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”
    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:

    D8B5FCAB-5019-459B-880B-1E2374A440D0.jpg

    F9F401A5-7AF9-4080-99DC-75A0EC7F89E1.jpg

    BB88626F-1A78-457C-8A5C-BBBD78447C2A.jpg

    F178118F-9FA2-4FEE-8CAD-D9EF5351AE26.jpg

    8B3C235D-FCAA-4119-88D2-2982D6A09444.jpg


    See Post #12 for balance of pics

    S.F.
    Last edited by StolenFox; 07-01-2017 at 04:59 PM.

  8. #8
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”

  9. #9
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”
    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.

    ACB03105-2561-4355-A944-85D02B388546.jpg

    626EA0E9-703E-410A-BAEB-59D21B114548.jpg

    F084AE29-413F-444B-AF46-0F3620B71073.jpg

    7067DADC-4F6E-403A-BD91-7407F104B46B.jpg

    AC10268D-DF4B-4D13-BCD8-76634E809C22.jpg

    See Post #14 for overflow pic.



    S.F.
    Last edited by StolenFox; 07-01-2017 at 05:01 PM.

  10. #10
    Join Date
    Apr 2012
    Location
    Stuttgart, Germany
    Posts
    577
    My Cars
    1997 M3 / 5.3
    Neat project...you have quite the skillset!

  11. #11
    Join Date
    Jul 2013
    Location
    FL Gulf Coast
    Posts
    1,205
    My Cars
    E36 - 1998 328iS - LS2
    Note to self: Must Learn To Weld.

    Tipsy

  12. #12
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”
    Overflow pics from Post #7

    83E310B4-E898-4E74-8906-18D3A02883EE.jpg

    0E769B62-A7AD-4B2B-B682-93FBB17CFB49.jpg

    F91091BD-F2C8-4025-833D-B4D54435908E.jpg

    18E9335C-5687-4480-A50B-ED450D828BCC.jpg

    Overflow pic from post #8
    3E64B057-B637-4A39-98B4-12AA6B3AFA73.jpg

    Quote Originally Posted by Tim Mc View Post
    Neat project...you have quite the skillset!
    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...

    Quote Originally Posted by TipsyMcStagger View Post
    Note to self: Must Learn To Weld.
    Tipsy
    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.

    S.F.
    Last edited by StolenFox; 07-02-2017 at 10:15 AM.

  13. #13
    Join Date
    Aug 2005
    Location
    VA
    Posts
    18,137
    My Cars
    E63AMG/Z31/Tacoma/F31
    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.

  14. #14
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”

    Today's project: 4L80E disassembly

    Overflow pic from post #9

    7C0BA976-206E-4BBC-879E-26A3D8E6B4DA_1.jpg


    Started tearing down the transmission today. What have I gotten myself into?

    A0D47FCD-AB75-44B3-9547-9C9088B07901.jpg

    C9D63799-01D9-4ECC-8E99-0EA6DEDCA7E2.jpg

    Also unhooked everything from the engine so I can get it pulled off the run stand.

    S.F.
    Last edited by StolenFox; 07-02-2017 at 10:17 AM.

  15. #15
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”
    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.

    9D50130E-A013-4410-B12E-9C96281A2EFD.jpg

    FD0CAFB6-2EE4-4EC0-9AC9-9976363ECA33.jpg



    S.F.
    Last edited by StolenFox; 07-02-2017 at 09:07 AM.

  16. #16
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”

    While waiting on transmission parts:

    I built the PCM and fuse block mounts:

    1B31B1B7-1BC8-4FC5-A266-E39EEDFC9947.jpg

    5991AFB3-9FE2-4CBD-89A8-4C79766E629C.jpg

    85CF5B4A-9FBE-440E-AAC0-60490F2AC4EC.jpg

    DD864C08-CD38-4F2B-8A43-C10E649E3275.jpg


    You guys with the Gen 4 (E38 & E67) pcm's got it made with those tiny computers, this Gen 3 is huge!

    S.F.
    Last edited by StolenFox; 07-02-2017 at 09:13 AM.

  17. #17
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”

    Small update:

    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.

    CFD65CBE-9B32-43B8-9652-EE59C77594BF.jpg

    C144643B-3CFF-4574-B4BD-5ADDE9CE693A.jpg
    BCCA852D-DB4C-468F-AA68-0E8184F5C25E.jpg


    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.

    AD2E2B83-0701-49C2-9B6D-C5042AD9160A.jpg

    33B5E56A-7EAD-4857-A285-81C352373D04.jpg

    S.F.
    Last edited by StolenFox; 07-02-2017 at 09:20 AM.

  18. #18
    Join Date
    Oct 2008
    Location
    West coast
    Posts
    1,316
    My Cars
    '00 540 6.0/4L80e/S480
    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!

  19. #19
    Join Date
    Jun 2011
    Location
    Buffalo, NY
    Posts
    1,703
    My Cars
    2001 BMW 540i/6
    yeehaw! keep it coming.

    2001 BMW 560i 6.0 LSx/T56 SOLD


    2000 Corvette Hardtop FRC

  20. #20
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”

  21. #21
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”

    Little update:

    DSC pump relocation and radiator bracket rough in:

    9A394484-986D-4619-8F14-FDF9339F1114.jpg

    E71E1A54-2763-4AB8-B894-A64AED223DC8.jpg

    S.F.
    Last edited by StolenFox; 07-02-2017 at 09:28 AM.

  22. #22
    Join Date
    Dec 2014
    Location
    Cave Creek, Arizona
    Posts
    1,990
    My Cars
    2008 E90 335i
    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
    Racing
    coilovers, 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

  23. #23
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”

    This weekends project: final radiator modifications

    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.

    1FEB52A9-BB64-4B28-83B0-95FDF82F0C9A.jpg

    3B4CEB45-2B8A-4B8F-A4EB-05EFDC39F16F.jpg

    C60DC060-68D3-47F4-9B5B-418166D7AB8A.jpg

    32C0ED7F-6229-4148-AA84-203F2D879E78.jpg





    S.F.
    Last edited by StolenFox; 07-02-2017 at 09:34 AM.

  24. #24
    Join Date
    Jun 2011
    Location
    Buffalo, NY
    Posts
    1,703
    My Cars
    2001 BMW 540i/6
    That filler looks awesome.

    2001 BMW 560i 6.0 LSx/T56 SOLD


    2000 Corvette Hardtop FRC

  25. #25
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”
    Quote Originally Posted by nsogiba View Post
    That filler looks awesome.
    Thank you sir!

    S.F.

Page 1 of 8 12345678 LastLast

Similar Threads

  1. My e39 LSx swap
    By M5Hunter in forum Engine Conversions
    Replies: 698
    Last Post: 02-10-2021, 03:14 PM
  2. My E39 LSx Turbo Swap
    By 02PRUV in forum Engine Conversions
    Replies: 51
    Last Post: 06-29-2015, 04:34 PM
  3. Replies: 61
    Last Post: 06-03-2011, 03:42 PM
  4. My E39 Double DIN Build (Avic & Janus!)
    By taylorwilsdon in forum 1996 - 2003 (E39)
    Replies: 40
    Last Post: 09-16-2009, 05:36 AM
  5. My e39 audio build
    By jLace in forum Car Audio & Electronics sponsored by Bavsound
    Replies: 0
    Last Post: 03-24-2007, 06:36 PM

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •