Well; finally after many months she returns to us appearing as a completely difference gal. During her time away she received far more than a paint job but rather a complete new look. She had her rear end widened so as to accommodate the huge wheels and tires as well and numerous other very cool personal touch items. Once of the most time consuming items tended to while she was away was the creating of the carbon fiber rear spoiler that was unique to this gal. The gal's owner worked relentlessly with us as the process which at times was extremely frustrating unfolded until finally his dream became a reality.

Now that she is back the process of completing the integrating of the numerous supercharger systems as well and the final list of personal touch items will be tended to however before we do anything we will be wrapping much of her in clear plastic with our focus being on the anticipated high risk areas before we begin to massage her again.

Here you can see the level of detail and concern provided during the plastic film installation process. There were no pre-cut pieces used but rather this process is in the truest sense custom and unique to this gal. The bonnet was not wrapped in these pictures because we want it to be a full seamless pieces as such have to wait for additional 54" material to arrive. We found the rolls that we had on hand had blemishes as such had to be returned to the manufacturer. [ View Pictures ]
Here is the gal's heart ready to have the secondary systems integrated and brought on line. Even without the bonnet being wrapped we are able to being the process of massaging her again however the first things that we did was remove her front bumper so as to insure that no damage is caused to it during this process. [ View Pictures ]
Now we will be integrating the intercooler system's circulation pump, the AquaMist water injection system, new HID lower driving lights, a pair of the clear lens high intensity headlamps, and a discretely integrated front and rear radar system. During this time we will also be tending to a couple final touches that need to be tended to within her interior. We need to integrate the custom leather and top stitched Cobra seats as well as a custom perforated leather and carbon fiber steering wheel designed to integrated with the custom carbon fiber trim and stereo/NAV system that we integrated earlier in this project.
It took us several attempts however we finally received nice quality 58" material so we could wrap the gal's bonnet.
Here the process of wrapping her bonnet with plastic film is underway. [ View Pictures ]
Now we will be tending to another personal touch item. In this case we will be "integrating" a radar and laser detection system within this gal. The goal (even though she will be noticed) is for her owner to know in advance who is looking at her whenever possible. Now not being a fan of most radar and laser systems because of the lack of OEM integration we go to great lengths to address this concern.
In order to integrate the radar/laser system we needed to get back into the gal's wiring heart. Because of this we will also be integrating the TV tuner as well as completing at least one more personal touch item to her new instrument cluster. The radar/laser control panel has been placed where it is easy to use and see as a component of the cockpit environment and yet equally easy to make all but disappear at will. [ View Pictures ]
Well after several discussions regarding the final personal touch items that this gal is receive a road map has been created as such the final phase of this project is underway. We will be completing some of the known wiring and integrations issues that resulted when we converted her from a E39 540 into a 39 M5 and at the same time introducing a few more E39 M5 specific items such as the instrument cluster. Now even this process created a bit of a challenge because it required the instrument cluster from an E39 M5 the lens cover from an E39 540 and the customer furnished carbon fiber face that now ties in beautifully with the custom black carbon fiber trim and the custom black carbon fiber and black leather steering wheel. It is also time to integrate the custom upholstered Cobra Misano seats.
Here is a portion of the uniquely machined strut bar that was then powder coated red to match the gal's valve covers aka "The Redhead". We wanted a subtle yet significant difference so that it would be seen and yet be the focal point within a stunning engine bay. [ View Pictures ]
Here Ash is very carefully integrating the black carbon fiber instrument cluster face and the associated trim rings prior to the instrument cluster being integrated into the gal. [ View Pictures ]
Here Noe is methodically tending to several of the final electrical conversion issues as well as upgraded the new clear Hella headlights that will adorn her nose. [ View Pictures ]
Here a myriad of dash related items are being tended to. The custom E39 M5 instrument cluster is being installed, the Pioneer Z2 audio system is being updated and converted to fully time video operation, the secondary systems such as TV and iPod are being brought on line, and an OEM E39 M5 interior rear view mirror was installed. [ View Pictures ]
Here are the fruits of the labor and the view as will now be enjoyed by the driver. [ View Pictures ]
Here the process of integrating the custom upholstered Cobra Misano seats is underway. [ View Pictures ]
We continue to complete many of the personal touch items; in this case we have integrated the carbon fiber lower from spoiler and the custom powder coated mesh grill. As a finishing touch we are incorporating a pair of machined aluminum struts between the leading edge of the carbon fiber spoiler and the upper/inner portion of the opening in the bumper.
Here we have integrated the carbon fiber front spoiler and the custom powder coated mesh grill. All that remains here is the integrating of the machined aluminum struts. [ View Pictures ]
We continue to methodically reassemble the gal for the final time. With all of dry fitting having been completed this phase is when all of the details appear.
Here we have a special blend of Hysol being prepared for the bonding of the custom machined aluminum bungs into the custom carbon fiber intake and discharge tubes. [ View Pictures ]
Here we have methodically integrated the custom machined aluminum bungs for the supercharger by-pass system as well as the AquaMist water injection nozzles into the custom carbon fiber intake and discharge tubes. [ View Pictures ]
Here we have installed the custom carbon fiber intake and discharge tubes for the final time as such all of the secondary plumbing and hardware is being reintroduced at the same time. [ View Pictures ]
Here the custom intake system has been integrated. [ View Pictures ]
Here we have integrated the AquaMist water injection pump onto the bumper reinforcement. This is an ideal location as it receives good air flow and remains accessible for service should the need arise. [ View Pictures ]
Here we have installed the bumper reinforcement as well as the custom heat exchanger for the last time as we continue to make this gal ready to be exercised. [ View Pictures ]
As we continue through the final assembly process occasionally we still find a detail item worthy of integrating. In this case we decided to change the OEM tan carpet to OEM black and at the same time change the lower transition trim pieces at the door sills, the B pillars, and the foot well areas. This also included the very nice m5 specific dead-man pedal.
Here we are removing the old carpet so as to make her ready for the new OEM black carpets. [ View Pictures ]
Here we have fully integrated the new OEM black carpets and OEM black trim along with the custom front and rear floor mats. [ View Pictures ]
Here are completing the assembly of the front bumper which includes the custom aluminum struts. [ View Pictures ]
Here we are integrating a pair of scuff plates to protect the high risk area of the carbon fiber lower spoiler. [ View Pictures ]
Here we are integrating the AquaMist water injection draw line from the OEM washer reservoir to the AquaMist pump neatly mounted within the front bumper reinforcement. [ View Pictures ]
Here the 3 secondary relays have been integrated thus bring the water injection, intercooler pump, and the primary electric fan on line. [ View Pictures ]
Here the final pieces of the custom radar and laser detection system have been integrated. [ View Pictures ]
Here the custom steering wheel has been fully integrated. [ View Pictures ]
Here the nose of the gal is being installed for the final time as we continue with the final assembly process. [ View Pictures ]
Here a the OEM washer nozzle wiring and hoses have been modified and neatly routed and secured under the carbon fiber bonnet. [ View Pictures ]
Here the custom Cobra seats are being fit. [ View Pictures ]
Over the next several days we will be putting the final pieces of the puzzle into position as we make this gal ready to head home.
Here the work within the DME compartment has been completed; all secondary systems have been integrated and the proper operational status of the systems confirmed. [ View Pictures ]
Here we integrated a black leather center console armrest into the gal to complete the contrasting interior layout. This was a last minute request as such we had previously used the area under the armrest for secondary electronics so we were not able to use the factory cubby style setup as such we modified the existing armrest slider to accept the new black leather armrest. [ View Pictures ]
Here the ///M 5 badge has been installed on her boot-lid. [ View Pictures ]
Here the area within the driver side wheel well has been completed and is now ready to be sealed with the inner fender liner and lower body panel. [ View Pictures ]
Here the oil filter drain line is being integrated; we do this because we relocate the oil filter housing from the driver to passenger side (USA version gals) during the integration of the supercharger system which then eliminates the ability for the oil filter housing to drain back into the pan as such an easy to access bulkhead fitting is integrated. [ View Pictures ]
Here the gal's engine bay has been completed; all fluids installed and she has been once again brought to life. [ View Pictures ]
With the engine bay integration completed her placard is finally put in place. [ View Pictures ]
Here she is being made ready for the last detail items before she begins her journey home. [ View Pictures ]
We are continuing to tend to all of the final detail and personal touch items as this gal is only days away from going home.
Here Branson is methodically removing all of the old window tint so as to make her ready for not only fresh tint but also darker tint. We decided to use limo tint through the rear of her and medium tint on the two front doors so as to insure reasonable visibility for the pilot. [ View Pictures ]
During the integrating of the Cobra Misano seats we found that the OEM steering column functions quit working. After much research we found that we needed to integrate an OEM body control module so that the proper signals could be generated. We decided to locate the body control module under the carpet just in front of the driver seat. This is a safe out of the way place and yet remains accessible for service over time.
Here we removed a small section of the hard Styrofoam located within the floor cavity and then fit a piece of extremely soft high density foam for the module to both rest on and be wrapped in prior to the carpet being put back into position. [ View Pictures ]
Here we had to create a custom wiring harness for the body control module as well as the seat belt notification system. Once completed using OEM connectors the entire assembly was integrated making her now ready to receive her driver seat for the last time. [ View Pictures ]
Now we will be completing the integrating of the Cobra Misano seats; this has been a very challenging phase of the project for many reason some of which are the fact that the seat design is such that extremely careful placement is required so as to insure the fore and aft movement with no interference. This is because the sport seats are much broader at the shoulders and at the thigh bolsters. Then add to this integrating the OEM seat belts; particularly the OEM Nitrogen charged latch side would prove to be difficult because once again the amount of available free space is slim and none. In any case; thanks to Tony and his ambitious team within VAC Motorsport a set of universal floor mount adapters were received that allowed us to manipulate the seat placement until everything worked and fit perfectly. Once this phase, the dry fitting/mocking up was completed Brian; a member of the VAC Motorsport team worked relentlessly to create the custom floor mount adapters in record time. He created a set of custom CNC machined billet aluminum floor adapters just for this gal. Now the mounting of the outer seat belt was relatively easy however as projected the inner seat belt latch mount provided both VAC Motorsports and our team several challenges. Finally with Greg and Mark initially working within the Solid Works program and then throughout the machine shop success was realized. In our opinion the combined aka team effort produced far more than simply stellar results but even more so the team effort created exactly what this phase required.
Here are a few of the steps as we complete the integration of the Cobra Misano seats for the last time. [ View Pictures ]
Here the Cobra Misano seats have been fully integrated. [ View Pictures ]
Now we will tend to the final detail items as well as the final detailing as this gal is heading home in a few short days.
Now we are going to install a custom D/A windshield visor banner as one of the final personal touch items requested after which she will run through her paces one last time before she is made ready to go home. During the final stage we will verify that all primary and secondary systems are on line and operating properly and then the last thing that we so is hook her back up to the GT1 and let BMW tell us that she is truly happy.
Here the windshield banner is being fit into position. [ View Pictures ]
Here she has just completed her physical and she passed with flying colors; she is running, at normal operating temperature, and happy as evidenced by these pictures. [ View Pictures ]
Here is a short video of her as she remains running; there is no doubt that she is ready to go play and that her owner is anxiously awaiting her arrival home.
Here the process of installing the windshield banner is being completed. During the process of installing the banner Evan elected to make a change as such a new banner was created and installed before all were happy with results. The banner was made a bit darker gray and the layout of the banner was also altered. [ View Pictures ]
Now that the project as defined has been completed we will now complete the final detailing as she will be loaded with the transporter in what soon will be a matter hours.
Now we are going to have the final phase of this project tended to; the vacuuming and then recharging of the a/c system at which point all OEM and newly integrated systems will be on line.
Here Victor carefully inspected and vacuumed the system prior to placing a fresh load of R134A into her system. As the result of this the final phase of this project has been completed as such she is truly ready to travel home. [ View Pictures ]
As with all projects a portion of them remain with us forever and in the case of this gal because of her time with us and the extensive amount of work completed she will be not only remembered but also missed as the days roll by. Sadly the weather is such that she had to be loaded in-between rain showers while still drizzling under the cloak of darkness as such wonderful pictures of her departing were not possible.
Here she is being secured within the transporter as her trek home is about to begin. Even though at her core she remains the same gal she has been completely revitalized, refreshed, and transformed; a gal that her owner has yet to meet and yet we are certain that they will play well together. [ View Pictures ]

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