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-   -   540i e39 dual exhaust conversion (my conversion) (http://www.bimmerfest.com/forums/showthread.php?t=662976)

blingin96 12-08-2012 05:47 PM

540i e39 dual exhaust conversion (my conversion)
 
10 Attachment(s)
Hello all, I have been thinking of doing it but the thinking has got the best of me.
Last month I did the front and rear M5 bumpers with some other bells and whistles. When I got to the rear bumper having only one exhaust outlet was KILLING me. So much that I never installed the rear diffuser.
Today I cut the other outlet on the diffuser then got carried away. I took out the tape measure and started cutting a piece of sheet metal. I AM going to keep the full size spare in place. I did not finish the job BUT the sheetmetal is cut and ready to be welded in. The fabrication took a few hours but I think it's comin along fine.
Here are some progress Picts.

I plan on starting the welding and cutting the trunk on Monday.

blingin96 12-08-2012 05:56 PM

2 Attachment(s)
A couple more Picts.MORE to come.

Topaz540i 12-08-2012 06:03 PM

so you did a battery delete? how do you start your car now? jk

moots 12-08-2012 06:53 PM

wow....u are a brave man.i don't think my hands will do what my mind wants to......

as an alternative:
http://i962.photobucket.com/albums/a.../rhexhaust.jpg
http://i962.photobucket.com/albums/a.../lhexhaust.jpg
http://i962.photobucket.com/albums/a...bq9796side.jpg

blingin96 12-08-2012 09:40 PM

I still need to find some tips for the system. I'm searching eBay right now. ( I'm up for suggestions for the tips).,Tips get expensive!
I plan on keeping the resonator ( the lung looking piece) and cutting another hole on the opposite side similar to the M5 piece. I am not going to run any mufflers after that point. It just going to be straight out after the resonator.

Right now i have the (resonator) off and only running one of the rear silencers. It really isn't loud at all. So I figure putting the lung back on and two outlets out the back should be ok. This will also minimize the cutting and the size of the hole I will have to make in the trunk.

DHoang 12-09-2012 06:51 AM

Quote:

Originally Posted by moots (Post 7238417)
wow....u are a brave man.i don't think my hands will do what my mind wants to......

as an alternative:

:rofl: I likey !!!:thumbup:

blingin96 12-10-2012 11:23 PM

1 Attachment(s)
The outside red lines is the outline of my template. The inner red line is where I'm going to cut. This way I can fold it to my template to cover any gaps.

blingin96 12-10-2012 11:25 PM

1 Attachment(s)
After the cutting.

blingin96 12-10-2012 11:38 PM

6 Attachment(s)
I tack welded the template in place. Then hammered up the excess metal from the trunk to cover any gaps as my template was not perfect.
When I hammered up the excess metal it then fit perfectly. I then welded and applied a sealer ( its like automotive caulking) over the welds. This way I KNOW it's sealed and waterproof. I did the same on the inside of the trunk.
Tomorrow I will spray some rubberized undercoating just to make SURE it's all sealed and it will match the OEM undercoating. I could not spray it today as the sealer was not cured.

blingin96 12-10-2012 11:42 PM

2 Attachment(s)
Here it is without the undercoating. I test the rear diffuser and it looks great!! More Picts to come.

moots 12-11-2012 06:06 AM

Quote:

Originally Posted by blingin96 (Post 7238633)
I still need to find some tips for the system. I'm searching eBay right now. ( I'm up for suggestions for the tips).,Tips get expensive!
I plan on keeping the resonator ( the lung looking piece) and cutting another hole on the opposite side similar to the M5 piece. I am not going to run any mufflers after that point. It just going to be straight out after the resonator.

oh now i see.....i was wondering how a whole muffler was going to fit in the tiny space that you just cut out! but then again,wouldn't the setup be a"lop sided" and unbalanced ie no muffler on the rh side with just a straight pipe coming out from the "lungs"?:dunno:

this is interesting....most cut out a 1/4 of the trunk space to accomodate the muffler and sacrificing spare tyre space........

completed pics a must........

edjack 12-11-2012 09:36 AM

Quote:

Originally Posted by moots (Post 7242381)
oh now i see.....i was wondering how a whole muffler was going to fit in the tiny space that you just cut out! but then again,wouldn't the setup be a"lop sided" and unbalanced ie no muffler on the rh side with just a straight pipe coming out from the "lungs"?:dunno:

He did say he would run straight pipes from the "lung."

blingin96 12-11-2012 06:12 PM

I will be cutting another hole on the passenger side of the 'lung' then add some 2 1/2 pipes. Similar to the M5 lung with the two outs. Then to some tips.

blingin96 12-28-2012 10:49 PM

8 Attachment(s)
Finally completed this mod 2.5" piping and 2.5" DUAL TIPS!! I cut a hole in the LUNG looking resonator and added dual outs. It looks like a straight through design inside the resonator so I figured it would work. It sounds AWESOME!! No drone in the cab and its not too loud.
The sound is similar to deleting the lung resonator and one of the silencers BUT its a deep throaty sound!! Best part is I didn't have to buy any other mufflers. It REALLY does sound great.
Overall a great mod and project. Just measure twice or three times and start the cutting!!
I definitely have no regrets and would do it again in a heartbeat. I love the way my car looks and sounds!

Silverlight95 12-29-2012 12:38 AM

Great work with fabricating! Really turned out well. Sounds clips? :thumbup:

emmanouil 12-29-2012 01:17 AM

Nice work, welcome to the club of Quad Exhaust System :thumbup:
My conversion you can see here ;)
http://www.bimmerfest.com/forums/sho...6&postcount=64

blingin96 12-29-2012 05:03 PM

I hope this works. Video attached

Silverlight95 12-30-2012 01:09 AM

Quote:

Originally Posted by blingin96 (Post 7278059)
I hope this works. Video attached

sorry i dont see the video :(

Try posting it on youtube then posting the link maybe?

blingin96 12-30-2012 01:24 AM

I hope THIS works!!

http://www.youtube.com/watch?v=v3G5S...e_gdata_player

Silverlight95 12-30-2012 01:56 AM

Quote:

Originally Posted by blingin96 (Post 7278773)
I hope THIS works!!

All better :thumbup:

Oh and that exhaust is probably the most aggressive sounding i have yet to hear on a 540. Seriously, how'd ya fit the lion in there? :D

mpower997 12-30-2012 06:07 AM

Quote:

Originally Posted by blingin96 (Post 7278773)

What year and milage are you workin with there?

blingin96 12-30-2012 06:38 AM

I have a 97 540i it has 112000k miles

Sent from my SPH-D710 using Bimmer App

mpower997 12-30-2012 08:23 AM

Any pics of inside the trunk with the battery installed, does it get hot?

blingin96 12-31-2012 06:26 PM

4 Attachment(s)
Inside the trunk picts. I just put it all together its the best I can do. The battery does not get hot. I drove it for about 2 hours today then I checked it. It felt like a cold battery. ;)

Sent from my SPH-D710 using Bimmer App

blingin96 12-31-2012 08:14 PM

3 Attachment(s)
The last picts.
Sent from my SPH-D710 using Bimmer App


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