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Old 12-11-2013, 05:08 PM   #31
Chris916
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Yea I think everything worked in the 540. Just so much easier to leave it out lol. I dealt with no a/c last year.. it wasn't so bad.
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Old 12-13-2013, 01:46 PM   #32
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Quote:
Originally Posted by Chris916 View Post
Yea I think everything worked in the 540. Just so much easier to leave it out lol. I dealt with no a/c last year.. it wasn't so bad.

it sucked being in the back - just sayin
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Old 12-22-2013, 05:24 PM   #33
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Haven't had much time to work on this, but I've made a bit of progress in the last few weeks. Lot's of prep going into the engine bay. Trying not to do same thing I did when building the racecar - "Ill just build this part to make it work for now, then come back later and redo it when I have the time" nope, none of that on this car. Just going to take the time to do it right up front. Not going to rush it.

Anyways, The pedal box assembly actually consumed a good amount of time. I have to move the fork mounting position on the brake pedal over 3.5" to accommodate the remote mounted booster linkage from the 540. With moving the fork location over, I had to move the clutch master cylinder over as well. Lots of measuring/cutting/welding.


Here is the stock pedal box


Clutch master cylinder mounting tab cut and moved over


New Attachment point for booster linkage fork


Built a bracket to move the master cylinder over






Everything painted
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Old 12-22-2013, 05:25 PM   #34
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Reassembled




Here is the stock mounting location of the booster.


Made a plate for the new mounting location.


Mounted the linkage assembly


Pedal box installed


Now I need to mount the actual booster and fit the linkage. This will probably wait until after Christmas. Pretty happy with the progress so far though.
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Old 12-29-2013, 09:13 AM   #35
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Got a bit more work done on the engine bay. I shaved a bunch of tabs off that will not be needed for the m60. Also cut the lip on the frame rail and seam welded it.













Got a bunch of new parts!



Control arms with delrin control arm bushings
New tie rods
V8 motor mounts and subframe spacers
Subframe reinforcement tabs
Poly motor mounts
Poly tranny mounts
Poly Subframe bushings
Poly Diff bushing
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Old 12-29-2013, 09:13 AM   #36
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Started to strip down the motor for a test fit



And dropped it in!





It's a tight fit (TWSS)









That's all for now. Ill be doing some more work today, hopefully finishing up the brake booster setup.
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Old 12-29-2013, 10:55 AM   #37
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Cool! Will the d/s header clear the steering shaft?
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Old 12-29-2013, 02:02 PM   #38
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Looks good! What engine mounts (rubber) are you using?
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Old 12-29-2013, 05:40 PM   #39
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Thanks! I won't be able to use the stock steering knuckle as it's too big. Ill also have to do some work to the headers since there are no stock headers that will work with this swap. I'm using Revshift m60 poly motor mounts.
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Old 12-29-2013, 08:10 PM   #40
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http://www.r3vlimited.com/board/showthread.php?t=273427

Check out my post for a cheap way of making a steering shaft. This gave me the clearance I needed. You can also make this any length you need.
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Old 12-29-2013, 08:39 PM   #41
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Great write up man! I was going to give that a shot since I saw another build that did the same thing, but it wasn't very detailed. Did you use x5 headers or modify the stock ones? The exhaust work is probably what I'm least looking forward to lol.
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Old 12-30-2013, 08:14 AM   #42
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I used modified E39 540 headers off an early non vanos car. I think the LH header is the same as the X5 header (a 4 into 1). I used a few U bends to make the most of the headers.

I had the most trouble with the RH header because you have to remove the engine to take the header off every time you test fit a piece. Mine could fit under the car better. I might fix it this winter.
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Old 12-31-2013, 05:21 PM   #43
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Yea not looking forward to that but it seems that the 4 to 1 is the way to go.

Made some more progress over the last few days. Finally have a functional brake setup.
I had to notch out the frame rail to accommodate the remote booster bracket. So I built a box for it to sit in, and welded 2 nuts on the back side to bolt it in.







Also had to make a bracket for the top bolts





And bolted it up



Next was to shorten the pushrod. Cut and weld.



Also cut/welded the extra support bar that now bolts to the strut tower (ran out of welding wire so I couldn't finish)

Here's everything bolted up and functional



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Old 12-31-2013, 05:21 PM   #44
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Dropped the motor back in to check clearance. This time with the tranny bolted up.









Since the 6-speed tranny is longer than stock, I had to move the tranny brace back. Drilled a couple holes, and welded nuts on the inside to bolt through



Next up, I need to figure out what ill be using for a rad and mock everything up. Also need to get an e36 steering rack and build the shaft, and then Ill start mocking up some headers!
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Old 01-01-2014, 09:41 PM   #45
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This is a epic transformation. Keep up the great work sir
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