So my seats looked like crap and needed to be dyed badly. Leatherique to the rescue!
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More pics to follow.
S.F.
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It's a ton of work but the results are worth it.
S.F.
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.
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Also have the 540i front brakes and springs to install.
S.F.
Last edited by StolenFox; 05-01-2018 at 07:36 AM.
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.
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Big difference in rotor diameter and thickness from 528i vs 540i:
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S.F.
Latest project is getting the 8.8 differential mounted into the spare subframe:
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Pics of the Diff mounted in the spare subframe to follow.
S.F.
I still the need to build the front mount but here's the 8.8 bolted in the spare subframe:
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S.F.
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
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.
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
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.
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S.F.
Last edited by StolenFox; 09-03-2018 at 08:12 PM.
Still slowly working on the diff project but wanted to show off the new rolling stock:
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S.F.
Last edited by StolenFox; 09-03-2018 at 08:09 PM.
Old:
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As delivered:
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Truth in advertising:
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Still working on the diff mounts/ 8.8 rebuild but might have just been sidetracked by a TR6060....
S.F
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.
Would you be comfortable estimating what the complete 8.8 conversion is going to cost you once complete? Great work!
The results of your efforts on your seats are incredible!!
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....
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.
Diff mounts & Subframe are finished. Diff still needs to be rebuilt though..:
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And, I bought a TR6060 that needed a little work off the Camaro5 board:
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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
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S.F.
Last edited by StolenFox; 09-03-2018 at 09:05 PM.
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
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.
Transmission swap has begun! 4L80E, shifter assembly, shift cable, TCI trans controller and custom switch panel will all be for sale soon.
S.F.
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
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.
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S.F.
That is quite a bit of detail for just one post! That clutch master reservoir bracket is sick!
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