Blackknight530i 530i6 -> M5 Conversion Build Thread

**Redshift** · 09-13-2016, 11:12 AM

https://youtu.be/mnQ2ZXlfW6E

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**philly98540** · 09-13-2016, 11:34 AM

It's alive! Congrats guys.

**purplecty** · 09-13-2016, 12:52 PM

Sounds mean!

**angeleye540i** · 09-13-2016, 02:01 PM

Hell yeah!

**golfgod** · 09-13-2016, 02:19 PM

Dude... You guys are beasts!!! What a project...I thought doing an M conversion on a 540 was difficult enough let alone on a 530....

Quick question, are you going to de badge it and put "sleeper" in its place?

**dk500** · 09-13-2016, 02:23 PM

Nice.

**gmak** · 09-13-2016, 02:36 PM

That little grin over the side of the A pillar says it all.

**auaq** · 09-13-2016, 02:59 PM

**TerraPhantm** · 09-13-2016, 03:25 PM

Originally Posted by blackknight530i

A lot of the wiring is the same as the 540i->M5 stuff, but since the 530i didn't have a starter relay, I noticed that the starter signal goes straight from the EWS to the starter, so I shouldn't have to do anything special for that.

I remember seeing in the wiring diagram that the S62 cars *do* have a start relay despite apparently not having auto start. I guess it works fine without that (you're basically wired as if an MSS54 right now).

**RVAE34** · 09-13-2016, 03:27 PM

Awesome!!

**Reefin Dude** · 09-13-2016, 03:36 PM

: i miss all of the good stuff.

that is an amazing amount of work you all have done!

G~

**blackknight530i** · 09-13-2016, 04:02 PM

Just got the car over to BPC in Raleigh for an alignment and hopefully AC recharge and possibly exhaust mating

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**auaq** · 09-13-2016, 04:29 PM

"Exhaust mating," I like that.

**blackknight530i** · 09-13-2016, 04:41 PM

My "M5" is trying to get its inspiration from a F10 M5 getting it's block sleeved for more power.

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**blackknight530i** · 09-13-2016, 06:49 PM

Just got back from getting the 530i rear section of the exhaust welded to the 540i cats I had on the 7 before and got an alignment. It isn't an ideal setup, but it will get me by for now until I get the m5 bumper on and get a proper dual exhaust done. That will require trunk floor modding, so it can wait until funds recover a bit.

Alignment is in spec, but only barely because we didn't get the steering column aligned to the steering wheel properly. At least it tracks straight and doesn't drone in the cabin.

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**cnsorial** · 09-13-2016, 06:56 PM

Originally Posted by blackknight530i

Just got back from getting the 530i rear section of the exhaust welded to the 540i cats I had on the 7 before and got an alignment. It isn't an ideal setup, but it will get me by for now until I get the m5 bumper on and get a proper dual exhaust done. That will require trunk floor modding, so it can wait until funds recover a bit. Alignment is in spec, but only barely because we didn't get the steering column aligned to the steering wheel properly. At least it tracks straight and doesn't drone in the cabin. Sent from my SM-N910V using Tapatalk

So, how's it drive!?!?

**dannyzabolotny** · 09-13-2016, 07:01 PM

Are you planning to keep the spare tire well, or are you going to transplant an M5 trunk floor pan? Whenever I get around to doing a full dual exhaust on my 540i touring, I want to keep the spare tire well, so I'll beat it with a hammer just enough to fit the second exhaust pipe. I plan to run muffler-less, so that should minimize how much space I'll need.

**blackknight530i** · 09-13-2016, 07:01 PM

Originally Posted by cnsorial

So, how's it drive!?!?

It drives great. The handling is amazing with the eibach bars and M5 steering box, but I don't have servotronic hooked up yet, so it's very stiff steering. It feels like I'm running super wide tires up front, but I'm only running 255s.

I still haven't swapped the fuel pressure regulator and pump yet, so no big WOT driving yet. Hopefully going to finish it tonight.

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**blackknight530i** · 09-13-2016, 07:09 PM

Originally Posted by dannyzabolotny

Are you planning to keep the spare tire well, or are you going to transplant an M5 trunk floor pan? Whenever I get around to doing a full dual exhaust on my 540i touring, I want to keep the spare tire well, so I'll beat it with a hammer just enough to fit the second exhaust pipe. I plan to run muffler-less, so that should minimize how much space I'll need.

Check out Redshift's build thread to see how to modify the floor properly for a dual exhaust. His was kind of pricey, but they basically welded a 4" diesel exhaust pipe section above the exhaust pipe. Then they undercoated and painted it.

I plan to cut the floor in a similar way, but the touring has a deeper floor, which has more space to still fit the spare wheel, while the sedan might not. I really doubt I'll be swapping out the trunk floor from a M5 though. That's a lot of work and I don't weld.

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**golfgod** · 09-13-2016, 07:52 PM

I wonder if you can just cut out a section of the spare tire well and turn it upside down...if you cut it equal that is...it's what I planned on trying when I do dual exhaust

**auaq** · 09-13-2016, 10:27 PM

Are you saying you'll have to redo the steering column again?? If true .... AWW HHELLLLL NAAWWWW!!!!!!

**blackknight530i** · 09-13-2016, 10:31 PM

Originally Posted by auaq

Are you saying you'll have to redo the steering column again?? If true .... AWW HHELLLLL NAAWWWW!!!!!!

Just the part under the steering wheel. Not a big deal.

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**blackknight530i** · 09-14-2016, 10:24 AM

Last night, I drove it from Raleigh to Charlotte to get it back home and it drove perfectly, with no weirdness or issues. I kept it around the speed limit and listened and smelled for any strange odors or sounds, but it was fine. I'll just say, there is no CEL, no DSC error, no brake warnings, no ill messages at all, except for the right turn signal light I forgot to reconnect when putting the headlight back in and now the connector is stuck. I'll get that fixed shortly. I also have a strange buzzing coming from the glove box area, but I think it's how I wired up the ebox fan. I admit I hadn't really thought it through that well, but since the 530i has a 3 wire ebox fan with a temp sensor in the ebox, I cut one of the locking tabs on the 2 wire plug on the M5 harness and just plugged it in how it would fit. I'm guessing that it's the issue, so I'm hoping to get a M5 fan from Adam shortly. We also stripped one of the axle bolts when torquing them down, so I need another one and the subframe bolts we expected to use to bolt it to the body weren't correct, so I'm also getting a full set of new bolts. The ones we put in work fine and were properly torqued, but just for safety sake, I'll swap them for the correct ones. I also need to get the AC recharged, which will hopefully happen in the next day or two, because it's still super hot and humid here.

So far so good guys!

**auaq** · 09-14-2016, 11:06 AM

Wish I was around to help you guys finish up the last few stuff, take a ride, drive, burnouts, donuts, getaway chase, street racing, going sideways, ..... you know how I like to roll.

**blackknight530i** · 09-14-2016, 11:07 AM

Originally Posted by auaq

Wish I was around to help you guys finish up the last few stuff, take a ride, drive, burnouts, donuts, getaway chase, street racing, going sideways, ..... you know how I like to roll.

Us too man! No crazy driving until I get the fuel stuff done. Don't want to run it lean and destroy the motor.

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