540i e39 dual exhaust conversion (my conversion)

Terrific job! We need more people who are not afraid of seriously working up their e39s opposed to just bolt-ons.

Nice Job, Looks good. do you have the specific dimensions you used when cutting the trunk, and the dimensions of the sheet metal insert piece?

Sorry no specific dimensions. I just took out the tape measure and did my best. If I remember right on the rear most of the car it was around 10" then bent that to a 'U' shape and on the front side it was around 16" then bent that to a 'U' shape. It was crude and really just pounding sheet metal until I got it close. It was a lot of pounding and cutting as you go to get it to fit. Just measure your template and make sure it fits where you want it. THEN do the cutting. I undercut about 1/2" of metal from the trunk so I could pound and fold it to fit my template. As my template was not perfect. It covered all the suspect areas.
It really was not as hard as people make it out to be.

found it bro!! Nice thread, I'm doing this this spring definitely.

My love for my 540 would go to another level if I got something like this done. Did you notice any HP gains?

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I have not put the car on the Dyno or anything BUT it FEELS like it added a few HP. Keep in mind it's 'cat back' only keeping the cats in place and only changing the back portion of the exhaust. If anything it reduces back pressure. It also SOUNDS 10x's better.

Great job on this. I read through it and it got the best of my interest. I know your's is a 540 and it sounds amazing but how do you think it would sound on a 530i?

you just helped me make up my mind about dual exhaust real nice sound man

Ive actually started on mines already, I hope to have a neat outcome as you did

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Not sure what it will sound like on a 530.. But the 540i sounds MEAN!!

Post up the progress and Picts!!!

I only want to ask abou the trunk and the spare tire !! How the trunk looks like !

Got some pictures of the inside of the trunk for you guys. Enjoy!!


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Thanks. One last question before I go try this on my own (maybe). What type of midpipes did you use specifically, and did you have to shape them at all to make them fit the way you wanted?

It's all custom bent 2.5" pipes after the 'lung' looking piece. My local exhaust shop bent it up and it fits great!
Stock exhaust manifolds, stock cats, then the lung piece, then it's all custom after that..

Alright, sounds good to me. Thank you for the help!

Update..
6-18-2013
The system is still in place with heat issues around the battery area. I bought some new high flow cats about a month ago and it still purrs like a kitten OR a very large cat.. LOL!!

Mate it looks great