This gal was delivered to us after numerous conversations with the gal's owner during which time we discussed where she has been, what has been done, and even more importantly he shared his dream of what he wants her to look and perform like when she finally completes her journey. It was as the direct result of these conversations that we agreed to have her shipped to us so we can spend a little time getting to know her during which time the conversations will ensue as we fully define the project. What we can say at this time is that she is already stunning to look at and that there have been several tweaks done to her thus far that already sets her apart from the crowd. The goal now is to complete the transformation process during which time there will be numerous personal touches incorporated into her as well.

Here she is as she arrived after her travels. She is very dusty from her time spent sitting in storage during the course of the defining stages of what is soon to be. [ View Pictures ]
Here she is getting her first bath in a very long time. As the dust and dirt rolls off her one can hear her say "I am ready for the next phase of this journey". [ View Pictures ]
After numerous conversations and much consideration the decision was finally made to pull the heart out of the 540 and replace it with a "Full Fledged" E39 M5 motor and not just any E39 M5 motor but rather one of our custom built "Red Head's". The motor will be fully blue printed and as a part of the block preparation we will install custom Darten sleeves, Arrow rods, custom spec'd CP pistons (ceramic faced with Teflon coated skirts) and custom selected rings, Schrick cams, and a fully machined set of heads that will be ported, flow matched, and 32 larger valves with matched springs and retainers installed. The rotating assembly will be balanced and then each of the bearings will be hand fit to insure the desired clearances resulting in an extremely strong base for the supercharger system that will also become a part of this gal. In addition to the gal's heart she will receive a new M5 transmission, a full SuperSprint dual exhaust (whereas the OEM 540 has a single exhaust at the rear) including small metal bed cats, with the drive trains power delivery will be managed through a UUC lightweight flywheel and multi puck clutch system. Over the next several weeks many more details will be defined which will include the ultimate gearing as well and the wonderful personal interior touches planned for this gal. But for now the project had to start somewhere so a complete running donor motor was purchased and the process has begun.
Here is the donor heart as received complete with wiring harness, alternator, A/C, etc. This was not just any donor motor but rather a running motor that we were able drive and give a physical or sorts before making the decision to make it a part of this project. [ View Pictures ]
Here the process of disassembling the heart in underway. For most you will never see the inside of an E39 M5 motor however for those that have been inside one or will one day it is on one hand a mechanical marvel and on the other an endless array of parts that once disassembled and sorted will fill several boxes. [ View Pictures ]
Here the heads stand waiting to be boxed prior to traveling to the machine shop however the block is already wrapped and tucked securely within the padded box sitting behind the heads. [ View Pictures ]
Now that the heart has been disassembled and the key pieces have been made ready for the machine shop here are the pieces of the puzzle that now need to be hand cleaned and inspected before tagging and bagging in preparation of the re-assembly process several weeks down the road. [ View Pictures ]
Here is a box full of pieces that have been labeled as trash. None of these pieces will ever find their way into one of our custom built "Red Head's". [ View Pictures ]
Now after completing much of the preparation work such as machine work for the "RedHead" and the many custom fabricated pieces to be installed during this project the project is now well underway. The phase presently underway is the assembling and installing of the custom "RedHead" motor during which time the OEM motor is being removed to make way for her new heart.
Here the gal has finally taken her place on the "Throne" as the sign that significant forward movement is about to commence. [ View Pictures ]
Here the custom heads are ready to be installed. It was during this process that complete porting and flow matching of the heads was completed, all 32 OEM valves were replaced with oversized pieces, and then cam specific springs and retainers were installed to control the movement now dictated by the Schrick cams. [ View Pictures ]
Here is the custom low compression pistons are ready to be installed. The tops have been ceramic coated for the purpose of adding a thermal barrier and the skirts Teflon coated so assist in the slippery movement and extremely low wear characteristics of this rotating assembly. [ View Pictures ]
Here the crank is ready to go. The journals were all micro polished and balanced. Because of the much lighter rotating assembly a significant amount of weight had to be removed from the crank as can be evidenced by the hole in what once was a Mallory plug in one of the crank throws. [ View Pictures ]
Here the fully blue printed block with the custom fitted Darten sleeves is ready for final assembly. [ View Pictures ]
Here the numerous core pieces have been inspected and organized as the final assembly of the "RedHead" commences. [ View Pictures ]
Here the nose of the gal is just about ready to come off. [ View Pictures ]
Here the core support and cooling cores have all been removed exposing the gal's old heart. None of the existing system will be used as a part of the supercharged "RedHead" soon to be installed. [ View Pictures ]
Here the OEM single exit exhaust is being removed as the new SuperSprint exhaust system starting at the headers all the way back will be installed once the necessary modification at the rear of the gal are completed so as to accept the dual mufflers. [ View Pictures ]
Here the process of removing the OEM rear bumper is underway. [ View Pictures ]
Here the OEM rear bumper has been removed and discarded as the replacement will be an OEM M5 bumper to facilitate the dual mufflers. [ View Pictures ]
Here the transmission removal is well underway. This transmission is being replaced with a "near new" OEM M5 unit and will be connected to the "RedHead" through a UUC lightweight flywheel and multi-puck clutch pack assembly. [ View Pictures ]
Here the gals old heart out including the original ESS supercharger system and ready to go to a "to be determined" new home. [ View Pictures ]
Here the gal's old heart, transmission, and misc core pieces have been loaded and are now on the way to their new destination. [ View Pictures ]
Now the gal is ready to be cleaned and prepped so as to receive her new heart aka "Redhead" further enhanced by the custom D/A supercharger system as seen on numerous other M5's over the past few years. Once this phase has been completed the transformation from 540 into a thoroughbred supercharged BMW inundated with a wonderful list of personal touches as defined by her owner.
Here the blueprinted block is now ready to have the crank installed. [ View Pictures ]
Here the crank has been installed and we are currently completing the torque sequence. [ View Pictures ]
Here the first custom piston is being installed. [ View Pictures ]
Here all of the custom pistons have been installed and the block is now ready for heads. [ View Pictures ]
Here the custom heads have been installed and now the secondary components are ready to be installed. [ View Pictures ]
Here the gal's heart aka "RedHead" is just about ready to be installed. [ View Pictures ]
Here the "RedHead" is being made ready to install. [ View Pictures ]
Here the heart aka "Redhead" of the gal in her new home. [ View Pictures ]
Here the SuperSprint headers are being installed. [ View Pictures ]
Here the M5 transmission is being installed after delays that came as the result of parts we found to be needed during the conversion process. IN addition to the transmission the SuperSprint headers are being buttoned up as well. [ View Pictures ]
Here the SuperSprint headers have been installed. Now we need to connect a few of the OEM sensors and install the slave cylinder as furnished by UUC to complete the light weight clutch and flywheel installation. [ View Pictures ]
During the next week several items will be tended to with the goal being to bring the gal's new heart aka "RedHead" to life late next week. Once the preliminary run in has been completed then the installation of the supercharger overlays will commence.
Over the last couple weeks during the Holidays the progress has been slow and yet progress has been made. Much of the time spent of late has been twisting and tweaking the gal back into shape. There were numerous twist and tweaks made during the course of previous modifications that needed to be corrected before true forward movement could be made. In addition to this several small issues have had to be dealt with and hardware conversions made to make the engine bay of this gal as would have been if an M5 from the onset. At this time we have much of the twisting and tweaking completed as such we have been able to move a bit closer to the day when the supercharger is put into place. Here the supercharger oil drain provision is being integrated into the upper portion of the OEM oil pan. The area was drilled, tapped and then the same fitting as located in the Vortech supercharger was installed which is connected between the oil pan and the supercharger with a piece of 1/2" ID hose. [ View Pictures ]
Here the SuperSprint small metal bed cats and the SuperSprint "X" pipe are being installed after a slight delayed that resulted from the need for some M5 specific pieces that were required as a part of this conversion process. [ View Pictures ]
Finally we have SuperSprint dual exhaust all the way back to the muffler section. All the remains with the front portion is the final alignment of the system and then tighten everything into place. As the project progresses the rear trunk/boot floor pan section will be replaced with the OEM M5 floor section thus allowing for the proper fit and OEM installation procedures. [ View Pictures ]
Here are a few of the pieces removed from the OEM filter lines and have be prepped for the integration stainless steel tubing and the "AN" ends so that the XRP HS-79 can be tied in as a part of the oil filter relocation process. [ View Pictures ]
Here is one of the many pieces that had to be modified during the supercharger conversion process. This particular piece is located within the oil pan and was originally a component of the OEM oil separator drain back system however with the supercharger conversion a custom oil separator and crank case breather system will be installed. [ View Pictures ]
Here the "RedHead" has been brought to life now breathing and pumping fluids on her own. The mechanical and electrical transformation from 540 to M5 has been successfully completed and as can be seen she has a "clean bill of health". [ View Pictures ]
Here the OEM Radio and the MID control unit in preparation of the new equipment slated to be installed into this location. In addition the center vent unit was removed because of previous damage and will be replaced as well. [ View Pictures ]
Here is another of the numerous corrective processes required during this gal's build. In her previous life a supercharger was installed during which clearances were an issue as such they cut the ABS motor/junction block bracket off and relocated it. Sadly the workmanship was less than stellar as such the bracket is about to be removed and then a donor OEM bracket will be located and installed back in it's original location.
Here is the bracket as it was relocated in her previous life. When installed by the factory it was a couple simple spot welds that held it into place however someone decided to MIG the entire seam during the relocation process as such this phase is a PITA. [ View Pictures ]
Here is the underside of the bracket as it was left by the person that previously relocated it. The braces were cut and left hanging, raw edges, exposed, in short a rough job. [ View Pictures ]
Here the bracket has been removed and now the area needs to be dressed so as to be made ready for paint and the installation of an unmodified OEM bracket. [ View Pictures ]
Here the area has been prepped and is now ready for final sanding, paint, and the installation of the donor OEM bracket. [ View Pictures ]
The owner of one of the extreme Supercharged M5's had to come in from out of town to take a peak at this project. After what seemed like (at least to me) forever as he walked around and around her we were finally given the "Thumbs Up" at which point Noah was finally able to relax and smile. [ View Pictures ]
Here you can see that we had to remove yet another OEM bracket from the right side shock tower that had been relocated by another during the previous Supercharging process. In addition we had to remove a couple OEM 540 brackets from the driver side as this gal's conversion into an M5 continues. [ View Pictures ]
Here the oil filter housing which was temporarily secured into place during the initial firing of the engine and the DCS compressor pump have been removed. The oil filter housing will soon be remounted on the passenger side once the new ABS brackets have been installed back into their OEM locations. The DSC compressor pump will be relocated under the driver side frame. In order for this to take place both of the OEM M5 DSC compressor pump brakes line were acquired and now will be slightly modified. FYI; the OEM placement for the DSC compressor pump is on the outside of the driver side frame rail however because of the supercharger's intake system it must reside directly under the frame rail for adequate clearances. [ View Pictures ]
Here the OEM oil filter housing, the DSC compressor pump, and the OEM 540 DSC compressor pump lines reside. Both the oil filer housing and the DSC compressor pump will be relocated however the OEM 540 lines will be retired from service as the migration of M5 pieces on to her continues. [ View Pictures ]
Here the OEM wood grained interior trim has been removed and is soon to be replaced with Black carbon fiber interior trim to match the evolving personality of this gal as well as the many personal styling "Qs" incorporated into this project . The black carbon fiber interior trim will find company within this gal along side such items as the new front seats that have fully exposed backs finished in black carbon fiber too. [ View Pictures ]
Here one of the many custom fabrication processes is underway. In this case the final stage of the custom oil transfer bungs are being completed. [ View Pictures ]
Here is one of the custom bungs used for the oil filter relocation process now ready to be installed as part of the oil filter relocation process. [ View Pictures ]
We are asked all the time what it takes to complete the supercharger conversion process which is a very difficult answer to share because in order to mechanically supercharge a car when compared to integrating systems in such a way so that they appears to be as OEM are two completely different approaches. We only integrate systems when compared to adding them on top of the existing as such h ere are a few of the custom designed and fabricated pieces and associated hardware required "only" to successfully complete the oil filter and power steering reservoir relocation process. In addition to this phase of the supercharger integration process there are many more that require a similar level of custom design and fabrication work. In this case we have pieces being completed for the two gals presently under the proverbial knife . [ View Pictures ]
In the pictures you can see that we use XRP's HS-79 line for the oil transfer process. This is an example of how we approach the conversion process because the HS-79 hose is many times more expensive when compared to other available options such as typical stainless steel braided hose. However the HS-79 is the lightest, the most flexibly which equals an increased serviced life, and has the highest flow rating per a given size because the inner diameter of the hose (when compared to a given size such as #10, #12, etc.) is the largest in the industry. [ View Pictures ]
Since this gal began her life as a 540 the OEM location for the DSC compressor (as can be seen in the first picture) was initially on top of the driver side (USA) frame rail. In the case of the OEM M5 the DSC compressor is located on the out side of the driver side frame rail (USA) . In both incidences the final placements needs to be below and just inside of the driver side frame rail so as to accommodate the custom air intake system for these supercharger conversions. Here you can see that the relocation process is underway. [ View Pictures ]
Here the custom DSC compressor bracket is now ready for installation. [ View Pictures ]
Here the DSC compressor has been mounted into place however it will remain loose until the OEM M5 brake lines arrive from Germany so we can complete this phase of the 540 to M5 to supercharged M5 conversion process. [ View Pictures ]
Here the OEM ABS pump support brackets are being Tig welded into place. Earlier in this project we shared that another facility had bent cut, twisted, and then relocated the OEM brackets in a rather disheveled manner as such they were all removed so that pristine OEM brackets paced back in their proper OEM location could be installed. [ View Pictures ]
Here the OEM brackets have been successfully installed and the ABS pump set into place for final fit. Now the ABS pump will be removed so the area can be properly prepped and painted before the final installation. [ View Pictures ]
Here we have removed the OEM A/C dryer bracket because during work done at another facility it was poorly modified. In addition it was no longer properly secured into place and furthermore the disheveled looking raw edges were never dressed or painted. [ View Pictures ]
Here is the OEM secondary air pump bracket that is supposed to secure to the underside of the AC dryer bracket. Sadly as can be seen in this picture it too was poorly modified and then when the secondary air pump was installed only 1 of the 3 mounting points was used as such the secondary air pump simply swung around akin to a monkey on a vine. [ View Pictures ]
Here is the new OEM AC dryer bracket ready to be installed as well as a picture allowing the comparison of both. It is truly very sad because in a case such as this the owner of the gal likely would never have known what was done previously because it is not a visible location. [ View Pictures ]
Here the new OEM AC dryer bracket and secondary air pump bracket is being properly installed with "no" modifications. [ View Pictures ]
Here the area that had the new OEM ABS brackets located back in their original location are being prepped for paint. [ View Pictures ]
Here the brackets and the surrounding area has been painted to an OEM color and texture. [ View Pictures ]
Here the ABS pump assembly is being reinstalled for the final time. [ View Pictures ]
Here the ABS pump assembly has been secured into place and all of the wiring was returned back as would have been on an OEM E39 M5. In addition power steering reservoir has been relocated; in this case we use one that is from a BMW Z8; it appears as an OEM E39 M5 reservoir however the nipples are angled differently. The original location for the power steering reservoir was located on the driver side (USA). [ View Pictures ]
Here is an example of the numerous custom pieces used throughout the supercharger conversion process. These custom cut gaskets rest on the top of the OEM throttle bodies and are sandwiched in-between the throttle bodies and the custom billet aluminum CNC'd intake manifold plates. [ View Pictures ]
Here are the custom billet aluminum CNC'd intake manifold plates as they are being installed on the "Redhead". These fully machined plates have been machined for o-ring sealing in-between the manifold plates and the lower plenum so as to insure proper sealing and also allow for ease of maintenance. In addition all of the threads have steel inserts so as to insure a long trouble free service life. [ View Pictures ]
Here the custom anodized CNC'd billet aluminum supercharger bracket has been fit for the first time along with the Vortech supercharger. Here is what some refer to as "Proof of Life". [ View Pictures ]
Here is the complete Ground Control system after being inspected and made ready for installation. [ View Pictures ]
Here the rear suspension is being tackled; at this phase the interior is being removed to garner access to the upper shock mount points. [ View Pictures ]
Here the rear Ground Control suspension has been installed. [ View Pictures ]
Here the installation of the front suspension is well underway. [ View Pictures ]
Here the front Ground Control system has been installed. [ View Pictures ]
All the ride height settings have been preliminarily made however once the gal has sat on the springs for a bit the final adjustments will be made and then the gal will be aligned before being deemed road worthy.
Here are the various OEM E39 M5 DSC compressor lines as received from Germany. Now they need to be custom bent to work with the relocated DCS compressor. [ View Pictures ]
Here the OEM M5 DSC compressor lines have been installed and the DSC pump is firmly in place for the remainder of the project. [ View Pictures ]
Here is the custom oil separator ready to be installed on the gal. [ View Pictures ]
Here the custom oil separator has been installed as it will remain throughout the remainder of the project. All it needs is to be freed of the extra thread sealant and it is ready to be plumbed. It was during this process that a mock-up supercharger belt is set in place to verify that we have adequate clearances. As the numerous secondary systems associated with the supercharger conversion process are installed clearances become a bit snug. [ View Pictures ]
Here the process of installing the XRP HS-79 oil transfer lines is underway. This is one of the many steps required during the oil filter housing relocation process. [ View Pictures ]
Here you can see the blue XRP lines being dry fit as the means to verify the placement of the stainless bracket used to secure them. [ View Pictures ]
Here the custom lower oil filter housing mount ready to be installed. [ View Pictures ]
Here the installing of the upper and lower oil filter brackets is underway. [ View Pictures ]
Here the oil filter housing is being dry fit as the means to confirm all fit associated issues prior to final installation and plumbing. [ View Pictures ]
Here the oil filter housing and the custom brackets have been mounted for the final time and the XRP HS-79 lines have been fit. The next thing is to have the ends crimped on the lines and then the power steering reservoir can be installed and plumbed. [ View Pictures ]
Here the XRP HS-79 oil transfer hoses along with the power steering reservoir and blue XRP hoses have been installed. At this point the oil transfer hoses have been fit into place and installed at both the custom bungs on the gals heart as well as the custom bungs located on the relocated OEM oil filter housing for the last time. However two pieces of the puzzle remain missing; there are two stainless steel securing plates being fabricated that will complete the hose securing assembly located at the leading edge of the oil pan at which time the 2 temporary zip ties holding everything into place will be removed. It will be at that time that the XRP stainless steel braided Teflon inserted #4 hose will be installed. This will be used to feed the supercharger with oil. In addition to these items the larger of the two power steering hoses has been secured into place at the power steering reservoir for the last time and also secured to the nipple at the rear of the power steering pump. The smaller of the two hoses will be secured under the oil pan once the stainless steel brackets have been completed however since it is ultimately routed and then connected to the power steering oil cooler on the driver side (USA) next to the radiator this connection can not be completed until the core support is back in place. [ View Pictures ]
Here the back of the gal has been completely disassembled in preparation of the removal of the OEM 540 trunk floor pan and in its place a new OEM M5 trunk floor pan will be installed. The purpose for this is to properly complete the gal's transformation from 540 into a M5 and in the case of this phase so that the OEM mounting points will be in place for the Super Sprint dual exhaust as well as the proper battery placement at the center rear of the gal. [ View Pictures ]
Here the engine bay was sealed up and made ready for her visit into the body shop. Several of the previously set into place pieces have been removed as a preemptive measure against damage which can be caused as the result of dust with in a body shop environment. Once she returns from the body shop the supercharger will be reinstalled for the last time and the installation of the various secondary systems will once again commence. [ View Pictures ]
Here the gal is at the body shop undergoing surgery within her boot area. During this phase the OEM 540 floor section is being removed so that the OEM M5 floor can be installed. [ View Pictures ]
Here is a component of the OEM M5 floor pan section prepared and ready to be installed once the remaining OEM 540 floor section has been completely removed and the area made ready for the new floor section. [ View Pictures ]
Here the process of the removing the OEM 540 floor section removal is well under way. [ View Pictures ]
Here the OEM M5 trunk/boot floor has been installed. Now we will be able to install the pair of SuperSprint mufflers as designed for an M5. The large opening in the center of the floor pan is where the OEM M5 plastic tub will be installed which will house the M-Mobility kit and the soon to be relocated battery. Certainly this process was more involved when compared to simply twisting and tweaking the OEM 540 floor pan section so as to accommodate the fitting of dual mufflers into the OEM M5 location however completing it in this manner retains the structural and cosmetic integrity of the gal. [ View Pictures ]
Here the interior of the trunk is in the final stage of the 540 to M5 conversion. During this phase interior trim pieces are being installed; in addition the original 540 positive battery cable that runs from the trunk through the cabin and under the passenger seat is being replaced with an OEM M5 cable because the battery is now fitted as an OEM M5. [ View Pictures ]
Here the "All" black carbon fiber GTR style hood created by Vorsteiner is being made ready for installation. The pictures do not do the looks justice as up close and personal it is truly a stunning piece of art work. [ View Pictures ]
Here the Redhead is having the supercharger and associated system installed for the last time. [ View Pictures ]
Here the full carbon fiber GTR style hood has been installed. Not only does it look stunning but it fits as well if not better than OEM. We were directed by another to use E46 M3 hood strut rather than OEM E39 hood strut because the OEM E39 hood struts are designed for a much heavier hood. As the result of using the E46 M3 hood struts the hood opens as closes smooth as silk. [ View Pictures ]
Here is one of the many cool little CNC machined pieces that bring this project together. This particular piece allows the OEM oil pressure sender and the supercharger's oil feed line to share the same OEM oil discharge port. [ View Pictures ]
Here the final assembly of the lower plenum is underway. It is during this process that the custom CNC billet intake manifold plates, the custom CNC machined velocity stacks, the custom CNC machined intercooler water transfer blocks and the custom intercooler are installed. We use a combination of custom throttle body gaskets and compliment of seal o-rings throughout this process insuring that the boost created is forced down her 8 individual throats aka throttle bodies. [ View Pictures ]
Here the installation of the right side OEM M5 muffler bracket is under way. It is been fit into position and now needs to have the final welding completed. [ View Pictures ]
Here the installation of the left side OEM M5 muffler bracket installation is underway. Unlike the right side the left side requires a placement notch be cut and finished prior to the final fit and welding of the bracket. [ View Pictures ]
Here the OEM M5 muffler shields are set into position verifying that everything fits as OEM prior to the welding of the brackets which is the final mechanical stage of this process and then the areas will be painted. Once this is completed the high flow SuperSprint mufflers will be hung in place which will complete the full SuperSprint exhaust installation as well as complete the transformation from single 540 exhaust into an true OEM M5 system. [ View Pictures ]
Here is the new OEM M5 radiator soon be installed in the gal. The 540 radiator removed has a much smaller core size as such the Redhead would never have been happy during the heat of the summer. [ View Pictures ]
Here is the new OEM M5 core support along side the original core support. We are replacing the core support because folks that worked on her in the past elected to cut off key pieces and also welded some rather ugly looking brackets. [ View Pictures ]
Here the final piece of the SuperSprint exhaust is being installed. The gal now breaths through a complete as designed M5 exhaust from the headers all the way through the SuperSprint high flow race mufflers. [ View Pictures ]
Here the final assembly of the gal's heart is well underway. The final plumbing is being installed with fluids soon to follow. [ View Pictures ]
Here the various fluids are being installed as we will bringing her back to life once again very soon. [ View Pictures ]
Now over the next 2 weeks the custom sound and navigation system will be installed which is one of the significant personal touches being completed on the gal.
Here the new custom black carbon fiber rear bumper diffuser based on the OEM insert has been completed and is now ready to be installed when the gal is ready for the installation of the final exterior pieces. [ View Pictures ]
Here IMO is a good sign of things to come; Ash, one of the fellows that I work very closely with when it comers to custom cabinet and stereo work is about as detail oriented as one can be. This is what a typical drawer of his tool chest looks like. [ View Pictures ]
Here the rear package tray has been opened up and modified so as to allow the proper porting required for the soon to be install JL Audio subwoofers. The OEM rear speaker were removed and replaced as well with JL Audio's finest. In the case of the new speakers they are separates as such a second harness had to be run on which a OEM speaker connector was used so as to insure the easy of future within this area. [ View Pictures ]
Here the numerous signal and video wires are being installed along the left side of the car. The reason that the left side is chosen is because the OEM power wires run along the right side so placing everything along the left side will control any potential electrical interference caused from cross bleed when wires are run along side of each other. The wires will be feeding and receiving signals from and for the amps, speakers, rear camera, and the cross over system. [ View Pictures ]
Here the custom subwoofer enclosure is under construction. Take note of how thick the plexi-glass is. This was needed so as to insure no panel deflection during those moments that the subwoofers are pumping hard. [ View Pictures ]
Here the JL Audio 500 watt single channel that has been allocated solely for the subwoofers can be seen as final measurements were taken. There is a much larger 4 channel JL Audio amp allocated for the primary speak system. [ View Pictures ]
Here Pioneer's latest Z2 stereo/navigation unit has been set into place. As can be quickly seen; there is much to be done to have the finished look appear as OEM and in addition to the Pioneer unit there will be two AutoMeter gauges occupying the same area. The dash trim and the surrounding trim for the Pioneer are all being completed in black carbon fiber. [ View Pictures ]
Here is an example of some of the wiring being used to successfully integrate the primary and secondary systems into this gal. One such secondary component is the XM Traffic module that can be seen. [ View Pictures ]
Here the OEM interior trim pieces are being made ready to install after having them all treated to an awesome black carbon fiber treatment. [ View Pictures ]
Here the latest JL Audio components are being installed in a methodical and very detail oriented manner. During this process the careful integration of the new systems with the existing space and OEM harnesses was carefully considered so that in the end there will reside an awesome sounding and looking system and at the same time maintain the OEM look as well as access to the numerous compartments located throughout the boot area. You will see that the primary 500 watt JL Audio amp is located behind the rear seat and fully trimmed in such a manner that when the seat is lowered it presents itself as wonderful eye candy and then the solo JL Audio sub amp was incorporated into the base of the subwoofer enclosure. Both amps were mounted and the surrounding trim was designed in such a way to insure proper air circulation during even the most extreme of music events. [ View Pictures ]
Here is Pioneer's latest offering; their AVIC Z2 after being carefully integrated into the OEM has now been secured in such a way as to allow for future service and to install that the unit remains stable. I should share at this point that this installation is not for the meek of heart. If an OEM style installation is the goal because the unit is large and required extreme work in order to successfully complete this process. [ View Pictures ]
Here the truly custom black carbon fiber closure/face plate is being fit into place. Within the panel will be a pair of Auto Meter gauges and the surrounding trim will also be black carbon fiber so the tie in and look in phenomenal. In addition to how the custom closure/faceplate looks it was designed to remain extremely easy to remove with no concern for damage for future service in a manner similar to what may have been offered as OEM. [ View Pictures ]
Here the back seat area is being opened to show the awesome systems primary JL amp installed. The picture show that the access is very user friendly and serviceable and then once the finish trim has been removed you can see the extreme attention detail maintained throughout. [ View Pictures ]
Here the boot area that was converted by us earlier to M5 specifications remains fully functional. You can see that the care a detail resides whether an exposed area or a place that most will never visit. The driver side rear now holds all the cross-over and is the place for the majority of the wiring and then in the right rear compartment is the battery junction block mounted on a very nice finish panel. [ View Pictures ]
Here the standalone JL subwoofer amp and the pair of JL subwoofers have been fully installed and all of the finish work has been completed. [ View Pictures ]
Now to say the system looks awesome would not even come close to how the system sounds as played through the Pioneer head unit supported by all of the JL audio components; phenomenal is the word that has been expressed by many. The system is feature packed with DVD, Bluetooth, Ipod interface, XM radio with traffic, backup camera, and navigation.
Here the custom carbon fiber intake tube is be cured under the heat lamp. During this process we are bonding a custom machined securing collar to the carbon fiber using a special mix of Hysol. [ View Pictures ]
Here the upper/ primary electric fan bracket is being fabricated so that once the gal returns from the painter this as well as the few remaining overlay systems can be installed thus making the gal to be exercised. [ View Pictures ]
Here the electric fan is being temporarily fit on another radiator so as to confirm that everything fits perfectly. The fan will be mounted using all stainless steel fasteners and the custom aluminum brackets. On the lower bracket is integrated a OEM BMW rubber isolator to eliminate transient vibrations and harmonics thus increasing the service life of the unit. [ View Pictures ]
Here the final assembly sits ready to be installed. [ View Pictures ]
Here are the new IForge wheels soon to be fitted with Pirelli tires so that the gal has some new shoes to be exercised on. [ View Pictures ]
Now there is no doubt in the minds of all that are aware of this gal's transformation that the project and the process has been extreme nevertheless as can bee seen in the following pictures; she is now visiting the body shop and the process she is presently under going will forever set her apart from the pack. She will be stealthy, wicked, BADASS, and to some they will think that BMW AG may have actually offered her as a limited edition but in the end she will be the only "ONE".
You will also notice the extreme care taken to protect all of the black carbon fiber surfaces that we just completed as part of this project by covering everything with painters tape. This care and attention to detail is just one of the many things that set our projects a part from the crowd. [ View Pictures ]
Here the new OEM bumper is being fit for the custom powder coated intercooler grill. Once this is completed then the bumper will be placed in the hands of the painter as the exterior detailing and styling changes continue to move forward. [ View Pictures ]
Here the custom powder coated grill has been temporarily installed so as to confirm that everything is perfect prior to final preparation and paint. [ View Pictures ]
Even though the gal remains in the hands of the body shop as she continues to be massaged other phases of the project continue to move forward. Here are the Misano's stunning Cobra seats as received from Italy . These were created using a wonderful mix of OEM style leather and Alcantera insets. In addition we had them completed using black thread for the Cobra logo and the perimeter deviated stitching. This was done for contrast and also to tie them in with the wonderful custom black carbon fiber accents now methodically placed throughout the interior of the gal. The primary structural portion of the seats were created from black carbon fiber and then the hardware is a nice mix of billet aluminum pieces and stainless steel. The process of acquiring these seats has been long (7 months) and at times frustrating as the first set that we received had white stitching as such they had to be returned only to have the arduous process repeated. [ View Pictures ]
During the gal's stay with the John at the body shop she is being made ready for a new coat of paint as well as some very cool exterior modifications.
Here the rear quarter panels have been stretched and then material added as we make room for the huge custom I-Forge wheels wrapped in 325 tires. During this process we retained the folded OEM exterior wheel opening lip and then had widened the rear bumper so that when completed one will sense that she could have come from Germany this way. [ View Pictures ]
Well; it has been a long time since we last updated this particular project. Not because nothing was happening but rather because over the past many months there have been numerous ideas considered as well as some trial and error massaging as such we elected to refrain from updating until we had a firm handle on the final direction that this gal was heading. Now certainly her heart and the fundamentals have always been know however in the end this gal's Poppa wanted her to be something very special.
Here she is having her hind quarters massaged. We decided that we wanted to give her a muscle car back end complete with huge wheels and tires however once completed we wanted her to appear as if she could have been presented this way from day one; an OEM feel as if truly a Motorsport exclusive. In completing the massaging of her hind quarters we also massaged her rear bumper so that once in place it will appear as if OEM rather than simply using some sort of add on wings that others have used to blend the rear bumper into a wider rear stance. [ View Pictures ]
It was decided that she needed a truly custom rear spoiler to compliment the rest of the project as such we began with a clean slate. It was also to be black carbon fiber to tie in with a few other subtle detail items being integrated as well.
Here is what we began with; a simple fiberglass release as taken off another E39. [ View Pictures ]
Here we are massaging away attempting to create the perfect spoiler for this gal. Bondo on, Bondo off. and the cycle was repeated over and over again as we completed one idea after another until finally. [ View Pictures ]
After creating numerous cool looking spoilers we found our self and the gal's owner creating what ended up looking very similar to the CSL spoiler as offered in Europe for the E46 M3. This was really not a huge surprise to any of us when you consider that the gal's back side (albeit larger) also resembles a E46 M3. In doing this we created a completed piece that in our opinion could have easily been presented by the team at BMW in Germany. At this point the handmade plug has been tendered to the composite team to convert it into a working mold so that from which can come a stunning black carbon fiber piece. [ View Pictures ]
Here the painting of the gal is well underway. She is being massaged from stem to stern with her color being transformed from OEM straight black to "Carbon Black"; a color offered by BMW as an option. Carbon black is a color that dances in the lights and accentuates her every line. During this process she was fully disassembled so that all of the jams could be tended to during this color transformation process and the individual pieces tended to one at a time. [ View Pictures ]
Here she has been painted and painstakingly color sanded and bluffed. During the painting process her custom IForge wheels were also treated to a custom color match within each of the spokes. Now we await a few trim pieces to be installed and then she will begin the final phase of her journey. [ View Pictures ]

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