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Go Back   Bimmerfest - BMW Forums > BMW Model Discussions > 5 Series > E39 (1997 - 2003)

E39 (1997 - 2003)
The BMW 5-Series (E39 chassis) was introduced in the United States as a 1997 model year car and lasted until the 2004 when the E60 chassis was released. The United States saw several variations including the 525i, 528i, 530i and 540i. -- View the E39 Wiki

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  #1  
Old 12-08-2012, 04:47 PM
blingin96 blingin96 is offline
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Location: Hayward
 
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Mein Auto: e39 540i , E36 328i
540i e39 dual exhaust conversion (my conversion)

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.
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Last edited by blingin96; 12-08-2012 at 04:54 PM.
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  #2  
Old 12-08-2012, 04:56 PM
blingin96 blingin96 is offline
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Mein Auto: e39 540i , E36 328i
A couple more Picts.MORE to come.
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  #3  
Old 12-08-2012, 05:03 PM
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Topaz540i Topaz540i is offline
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Mein Auto: 2001 540i/6
so you did a battery delete? how do you start your car now? jk
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  #4  
Old 12-08-2012, 05:53 PM
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moots moots is offline
wat's dat noise
Location: Malaysia
 
Join Date: Apr 2005
Posts: 451
Mein Auto: '97 528i
wow....u are a brave man.i don't think my hands will do what my mind wants to......

as an alternative:


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  #5  
Old 12-08-2012, 08:40 PM
blingin96 blingin96 is offline
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Location: Hayward
 
Join Date: Feb 2012
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Mein Auto: e39 540i , E36 328i
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.
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  #6  
Old 12-09-2012, 05:51 AM
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DHoang DHoang is offline
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Quote:
Originally Posted by moots View Post
wow....u are a brave man.i don't think my hands will do what my mind wants to......

as an alternative:
I likey !!!
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  #7  
Old 12-10-2012, 10:23 PM
blingin96 blingin96 is offline
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Location: Hayward
 
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Mein Auto: e39 540i , E36 328i
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.
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  #8  
Old 12-10-2012, 10:25 PM
blingin96 blingin96 is offline
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Mein Auto: e39 540i , E36 328i
After the cutting.
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  #9  
Old 12-10-2012, 10:38 PM
blingin96 blingin96 is offline
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Mein Auto: e39 540i , E36 328i
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.
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  #10  
Old 12-10-2012, 10:42 PM
blingin96 blingin96 is offline
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Here it is without the undercoating. I test the rear diffuser and it looks great!! More Picts to come.
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  #11  
Old 12-11-2012, 05:06 AM
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moots moots is offline
wat's dat noise
Location: Malaysia
 
Join Date: Apr 2005
Posts: 451
Mein Auto: '97 528i
Quote:
Originally Posted by blingin96 View Post
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"?

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........
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Last edited by moots; 12-11-2012 at 05:08 AM.
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  #12  
Old 12-11-2012, 08:36 AM
edjack edjack is offline
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Mein Auto: '97 540i 6 speed
Quote:
Originally Posted by moots View Post
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"?
He did say he would run straight pipes from the "lung."
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  #13  
Old 12-11-2012, 05:12 PM
blingin96 blingin96 is offline
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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.
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  #14  
Old 12-28-2012, 09:49 PM
blingin96 blingin96 is offline
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Mein Auto: e39 540i , E36 328i
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!
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  #15  
Old 12-28-2012, 11:38 PM
Silverlight95 Silverlight95 is offline
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Location: New Jersey
 
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Mein Auto: 2001 540i sport
Great work with fabricating! Really turned out well. Sounds clips?
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  #16  
Old 12-29-2012, 12:17 AM
emmanouil emmanouil is offline
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Mein Auto: E39 530i & E200
Nice work, welcome to the club of Quad Exhaust System
My conversion you can see here
http://www.bimmerfest.com/forums/sho...6&postcount=64
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  #17  
Old 12-29-2012, 04:03 PM
blingin96 blingin96 is offline
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Mein Auto: e39 540i , E36 328i
I hope this works. Video attached
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  #18  
Old 12-30-2012, 12:09 AM
Silverlight95 Silverlight95 is offline
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Quote:
Originally Posted by blingin96 View Post
I hope this works. Video attached
sorry i dont see the video

Try posting it on youtube then posting the link maybe?
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  #19  
Old 12-30-2012, 12:24 AM
blingin96 blingin96 is offline
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Mein Auto: e39 540i , E36 328i
I hope THIS works!!


Last edited by blingin96; 12-30-2012 at 12:33 AM. Reason: video didnt work
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  #20  
Old 12-30-2012, 12:56 AM
Silverlight95 Silverlight95 is offline
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Mein Auto: 2001 540i sport
Quote:
Originally Posted by blingin96 View Post
I hope THIS works!!
All better

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?

Last edited by Silverlight95; 12-30-2012 at 12:58 AM.
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  #21  
Old 12-30-2012, 05:07 AM
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mpower997 mpower997 is offline
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Mein Auto: E60 545i6/04 330ci
Quote:
Originally Posted by blingin96 View Post
I hope THIS works!!

What year and milage are you workin with there?
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  #22  
Old 12-30-2012, 05:38 AM
blingin96 blingin96 is offline
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Mein Auto: e39 540i , E36 328i
I have a 97 540i it has 112000k miles

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  #23  
Old 12-30-2012, 07:23 AM
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mpower997 mpower997 is offline
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Any pics of inside the trunk with the battery installed, does it get hot?
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  #24  
Old 12-31-2012, 05:26 PM
blingin96 blingin96 is offline
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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.

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  #25  
Old 12-31-2012, 07:14 PM
blingin96 blingin96 is offline
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The last picts.
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