DAS VADER: E39 Touring Build Log - Page 4 - Bimmerfest - BMW Forums



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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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  #76  
Old 02-19-2019, 09:21 AM
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ucsbwsr ucsbwsr is offline
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Location: San Diego
 
Join Date: Aug 2006
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Mein Auto: E61
Progress on the E39 has been a little slow as I recently picked up another E61 which is a short term refresh/flip project and has been getting most of the wrenching attention.

More here: https://www.bimmerfest.com/forums/sh....php?t=1314813

Here is a pic of the wagon stealing all the attention.


Back to the e39 it has received a few updates. I installed some Morimoto xb LED fog lights





My LUK DMF020 flywheel arrived.


...and the oh-so-important timing teeth


Stopped by VIP Modular/RSV Forged to assist with a headlight project. They are fans of wagons as well!
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N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Swap, MFactory SMFW, Spec Stg 3+ Clutch, Shiftteck SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Ethanol Sensor
- N54B30, JB4, Hexon RR550s, Custom Y-Pipe Inlet, AR DPs, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB PCV, BMS OCC

E39 540iT:
- OEM Style 167, KW V1
- E38 Contour Seats
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  #77  
Old 02-19-2019, 11:59 AM
SamD SamD is offline
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Hey Evan,

Outstanding work on ALL of the projects I've looked at in the various threads here today - not sure I've ever spent more time on any given thread as I have following your work on the wagons. Well done!

I'm VERY interested in your work on the headlights for the beater-turned-Cinderella e39 you've shared with the forum. I love the look of the lights, but got a little lost on your explanation of the conversion. My headlights on my 01 540 are the angel eyes ballasted HID projectors, but the light dispersion absolutely SUCKS! I've never seen lights that no matter the adjustment just don't light up much of anything. It's so bad that I really don't even like to drive at night unless I'm on the highway :-(

Will you point me toward a conversion for these units? I don't mind modifying what I've got, replacing them, whatever it takes to get some light on the road. Please give me some direction if you don't mind.

Thank you!
Sam
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...more fun with DSC off...


Last edited by SamD; 02-19-2019 at 12:01 PM.
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  #78  
Old 02-20-2019, 08:08 AM
LB-BMW LB-BMW is offline
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Absolutely great work. That is such a great looking wagon. I also would like to buy it when you are done playing!
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  #79  
Old 03-02-2019, 09:36 AM
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ucsbwsr ucsbwsr is offline
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Quote:
Originally Posted by SamD View Post
Hey Evan,

Outstanding work on ALL of the projects I've looked at in the various threads here today - not sure I've ever spent more time on any given thread as I have following your work on the wagons. Well done!

I'm VERY interested in your work on the headlights for the beater-turned-Cinderella e39 you've shared with the forum. I love the look of the lights, but got a little lost on your explanation of the conversion. My headlights on my 01 540 are the angel eyes ballasted HID projectors, but the light dispersion absolutely SUCKS! I've never seen lights that no matter the adjustment just don't light up much of anything. It's so bad that I really don't even like to drive at night unless I'm on the highway :-(

Will you point me toward a conversion for these units? I don't mind modifying what I've got, replacing them, whatever it takes to get some light on the road. Please give me some direction if you don't mind.

Thank you!
Sam
Thanks for the kind words. As for the headlights the first things to address are 1. Headlight aim and 2. New HID bulbs. There are lots of headlight aiming guides online but in a nutshell find a large white wall where you can park on a flat surface ~30ft away and shine your lights on the wall. Measure the height of the projector lens off the ground, alternatively walk up to it and let the light shine on your leg (probably around your knee) and then measure that height MINUS ONE INCH on the wall, mark it with tape. Raise/lower the vertical aim of the headlight until the top of both cutoffs are at that height.

As for bulbs, they fade over time and if your bulbs are original they could be emitting 1/2 the amount of light as new. Buy some quality D2S bulbs like the Osram CBI, CBB, or the Philips WHV2. They are not cheap but are worth the investment. Don't buy aftermarket bulbs like Morimoto etc. Also make sure to buy bulbs directly through the manufacturer on Amazon or better yet from The Retrofit Source, there are tons of knock offs on eBay and elsewhere.

Quote:
Originally Posted by LB-BMW View Post
Absolutely great work. That is such a great looking wagon. I also would like to buy it when you are done playing!
Noted!
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N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Swap, MFactory SMFW, Spec Stg 3+ Clutch, Shiftteck SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Ethanol Sensor
- N54B30, JB4, Hexon RR550s, Custom Y-Pipe Inlet, AR DPs, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB PCV, BMS OCC

E39 540iT:
- OEM Style 167, KW V1
- E38 Contour Seats
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  #80  
Old 03-02-2019, 10:10 AM
bobdmac bobdmac is offline
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ucsbwsr. That looks like some very fine work, extremely well documented. For additional inspiration, you might to check out this S62, 6-spd swapped 540 on Bring a Trailer
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  #81  
Old 03-02-2019, 10:51 AM
SamD SamD is offline
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Quote:
Originally Posted by ucsbwsr View Post
Thanks for the kind words. As for the headlights the first things to address are 1. Headlight aim and 2. New HID bulbs.
Noted!
First off, you're welcome. Great work!

As to your reply, that brings me to two questions:

1) I've got the aim dialed in pretty well, but I'd like to try your method. Do you suggest measuring from the center of the bulb to set my benchmark for height or from somewhere else?

2) As for the bulbs, I've run a quick search, and there seems to be a myriad of choices: 4300K, 5000K, 6000K, 8000K, etc. I feel like I'm driving with the parking lights on right now (maybe not quite that bad, but not far from it). I've always liked my lights VERY bright. Which way do you suggest? I like Phillips lighting and found this on a quick FeeBay search, but will go to Amazon to place my order:

https://www.ebay.com/itm/2x-New-HID-...MH-m:rk:2:pf:0

Thank you again! Sam
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...more fun with DSC off...

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  #82  
Old 03-02-2019, 02:32 PM
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ucsbwsr ucsbwsr is offline
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Mein Auto: E61
Das Vadr is still in a holding pattern while the grey one (Das Grau) gets all the love but a 6MT and engine refresh will be worth the wait.

But wait, there's more! Unbroken cupholders!


Full House!
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N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Swap, MFactory SMFW, Spec Stg 3+ Clutch, Shiftteck SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Ethanol Sensor
- N54B30, JB4, Hexon RR550s, Custom Y-Pipe Inlet, AR DPs, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB PCV, BMS OCC

E39 540iT:
- OEM Style 167, KW V1
- E38 Contour Seats
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  #83  
Old 03-02-2019, 02:56 PM
SamD SamD is offline
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That's a GOOD LOOKIN' house!!! I don't care what anyone says; that's a good lookin' house!!!!!!!!!
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...more fun with DSC off...

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  #84  
Old 03-02-2019, 03:20 PM
atobe atobe is offline
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Mein Auto: 00 528, 01 540
Just saw your YouTube build video yesterday, knew it had to be someone on the forum.
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  #85  
Old 03-19-2019, 04:14 PM
4thBMW 4thBMW is offline
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Location: FLORIDA
 
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Mein Auto: 2002 540iT Sportwagon
My wagon is a July 2002. No way the outer lense pulls off :(

Just swapped my original working low bulbs for CBI's. Still not satisfied....
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  #86  
Old 03-22-2019, 07:39 PM
4thBMW 4thBMW is offline
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Mein Auto: 2002 540iT Sportwagon
I went with 66240 CBI - 5500K

Noticable difference in light but my adjusters are screwd and I have the lamps tie-stripped to approximate correct alignment. What I need is a new lamp unit to utilize my HID 35 watt power and my bulbs. High bean Halogens throw good light. New facelift Hella's ar pricy.
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  #87  
Old 03-24-2019, 07:43 AM
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ucsbwsr ucsbwsr is offline
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Quote:
Originally Posted by 4thBMW View Post
Noticable difference in light but my adjusters are screwd and I have the lamps tie-stripped to approximate correct alignment. What I need is a new lamp unit to utilize my HID 35 watt power and my bulbs. High bean Halogens throw good light. New facelift Hella's ar pricy.
Sounds like you know what you need to do.
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N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Swap, MFactory SMFW, Spec Stg 3+ Clutch, Shiftteck SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Ethanol Sensor
- N54B30, JB4, Hexon RR550s, Custom Y-Pipe Inlet, AR DPs, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB PCV, BMS OCC

E39 540iT:
- OEM Style 167, KW V1
- E38 Contour Seats
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  #88  
Old 03-24-2019, 08:13 AM
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ucsbwsr ucsbwsr is offline
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Mein Auto: E61
As my other E61 wagons have been getting a lot of major work done progress on Vadr has been slow but steady. I am really pleased with where the build is at and excited to get a manual in this thing since it will completely change the character of the wagon.

The build is nearing completion and there is only a handful of major items to address before this thing goes up for sale.

- Timing chain guide/vanos refresh
- Manual swap
- Replace hood
- Replace windshield
- Recondition E38 comfort seats
- Install refinished M Parallel wheels


New aftermarket pork chops.


Found a nice deal on some E38 M parallels, they are currently being professionally repaired and powder coated Porsche Silver, I have a set of Hankook V12s, new valve stems, and new "M" stickers waiting in the garage for them. These will go on the E39 and the Style 167s will go over to the grey E61.


They fit like a glove in the cargo area.


If it clears, it clears!


New NGK plugs



During some spirited driving the main coolant hose cracked


During some musical wheels I decided to throw the 20" vossens on the E39. The rears looks sick but it would be challenging to stop them from rubbing.



Junkyard dayz! Picked up some missing black interior pieces and also scored an M60 intake manifold, it was already removed from the engine all I had to do was remove the throttle body.


Lower seat rail trim


E38 comfort seat backs needed some love


Some love they received. Pseudo fixed the sagging map pockets by screwing them into the "closed" position. Cleaned and conditioned leather.


Rail trim installed



Seatbacks installed



Replaced missing valve cover cover bolt cover. lol


As you might have seen in earlier photos Vadr was filthy and since there was finally no rain in the forecast it was time for a wash.


.....and you know what that means, some fancy photos where I take into consideration backgrounds, lighting, and making sure my iphone lens is clean. Heck I even installed tire treatment.





Shifter boot photo bomb







The hood has got to go

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N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Swap, MFactory SMFW, Spec Stg 3+ Clutch, Shiftteck SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Ethanol Sensor
- N54B30, JB4, Hexon RR550s, Custom Y-Pipe Inlet, AR DPs, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB PCV, BMS OCC

E39 540iT:
- OEM Style 167, KW V1
- E38 Contour Seats
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  #89  
Old 03-24-2019, 08:22 AM
pwgoo1 pwgoo1 is offline
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Mein Auto: 2003 525i Touring
Iíll ask before someone else does...and I know they will...

Where did you get the aftermarket porkchops, do they fit the M-Sport trim, and how much were they?

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  #90  
Old 03-24-2019, 10:19 PM
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computiNATEor computiNATEor is offline
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Quote:
Originally Posted by pwgoo1 View Post
Iíll ask before someone else does...and I know they will...

Where did you get the aftermarket porkchops, do they fit the M-Sport trim, and how much were they?

eBay, yes, and they're $85+$25 shipping.
https://www.ebay.com/itm/BMW-E39-M5-...d=323673232327
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Reliable P.O.S. - 1995 Camry V6. 260k mi+.
E39 M5 - TiAg/Schwarz Nappa (M1SW) 07-18-2001 M5 Heritage (BZ99672). 171,000mi and increasing daily.

Prior:
Black Sapphire/Schwarz 03-11-2003 530iA Sport (CK39185). T-boned 03-01-2017 at 155,861mi.
Toledo Blue/Sandbeige 04-25-2002 530iA Sport (CH98032). Sold 11-10-2017 at 147,743mi.
Toledo Blue/Grau 10-29-2001 530i5 Sport (CE92358). Sold 02-01-2019 at 217,600mi.
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  #91  
Old 03-25-2019, 02:14 PM
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ucsbwsr ucsbwsr is offline
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Quote:
Originally Posted by pwgoo1 View Post
Where did you get the aftermarket porkchops, do they fit the M-Sport trim, and how much were they?
Quote:
Originally Posted by computiNATEor View Post
eBay, yes, and they're $85+$25 shipping.
https://www.ebay.com/itm/BMW-E39-M5-...d=323673232327
Yup, those are them
__________________
N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Swap, MFactory SMFW, Spec Stg 3+ Clutch, Shiftteck SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Ethanol Sensor
- N54B30, JB4, Hexon RR550s, Custom Y-Pipe Inlet, AR DPs, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB PCV, BMS OCC

E39 540iT:
- OEM Style 167, KW V1
- E38 Contour Seats
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  #92  
Old 03-26-2019, 02:08 PM
garrickd garrickd is offline
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Quote:
Originally Posted by ucsbwsr View Post
Yup, those are them
Hey do you still know how to paint the headlights on the Tesla Model S?
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  #93  
Old 04-01-2019, 09:02 AM
ucsbwsr's Avatar
ucsbwsr ucsbwsr is offline
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Location: San Diego
 
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Mein Auto: E61
Got the family together for some pics. The black one, the grey one, and the fast one.

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N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Swap, MFactory SMFW, Spec Stg 3+ Clutch, Shiftteck SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Ethanol Sensor
- N54B30, JB4, Hexon RR550s, Custom Y-Pipe Inlet, AR DPs, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB PCV, BMS OCC

E39 540iT:
- OEM Style 167, KW V1
- E38 Contour Seats
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  #94  
Old 04-29-2019, 06:55 AM
ucsbwsr's Avatar
ucsbwsr ucsbwsr is offline
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Location: San Diego
 
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Posts: 402
Mein Auto: E61
Refreshed some OEM center caps (the top set)
Before


After


OEM Style 37s, E38 fitment which mean 72.56 and also a 9.5" rear as opposed to the usual 9" on the E39 which allows for E39 M5 spec tires on the M Parallels. Professionally refinished and powdercoated in "Porsche Silver." The BMW silver had a too much metallic flake in it, the Porsche is a sharper color with a metal like satin finish. No clear coat. 245/40 275/35 Hankook V12s.








Changing of the guard




Style 37s always looking sharp






Cleaned up the M60 intake manifold






New OEM lower seat trims and cargo trim pieces.


Before


After



Before


After
__________________
N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Swap, MFactory SMFW, Spec Stg 3+ Clutch, Shiftteck SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Ethanol Sensor
- N54B30, JB4, Hexon RR550s, Custom Y-Pipe Inlet, AR DPs, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB PCV, BMS OCC

E39 540iT:
- OEM Style 167, KW V1
- E38 Contour Seats
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  #95  
Old 04-29-2019, 02:39 PM
4thBMW 4thBMW is offline
4th BMW
Location: FLORIDA
 
Join Date: Aug 2010
Posts: 464
Mein Auto: 2002 540iT Sportwagon
Yow, You really get after it !

I seem to recall using extreme force on those bolts/ nuts you mention above..I ordered new nuts and had to use a breaker bar and jack handle -extension over it AND my leg to loosen the bolts. It wasn't until I had the rubber out of the car that I could see the hairline cracks around each bolt hole rubber 'mound' (see in pic if you blow up). Results were noticeable with the new auto-trans bushing.
Thx for the updates...interesting project(s). The OEM German parts works great.
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  #96  
Old 05-06-2019, 02:27 AM
0-60Motorsports 0-60Motorsports is offline
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Mein Auto: E46 M3
Amazing build journal and the Wagon looks great. Not a fan of the Beige interiors though....Black would look more "Vader"
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  #97  
Old 10-27-2019, 01:47 PM
cjhansen cjhansen is offline
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Mein Auto: 97 BMW 328i 5 speed sedan
Love the work you've done! How's the budget bushing/ control arm kityou installed holding up?
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  #98  
Old 02-26-2020, 06:20 PM
CurlyTopRob CurlyTopRob is offline
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Location: Atlanta
 
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Mein Auto: e36 vert, e39 sedan
Very Niiice!!! I got an e39 last year and am currently working on it. This was/is a nice build. Any updates on it since the last post?
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  #99  
Old 02-27-2020, 07:08 AM
4thBMW 4thBMW is offline
4th BMW
Location: FLORIDA
 
Join Date: Aug 2010
Posts: 464
Mein Auto: 2002 540iT Sportwagon
Nice seat job...

i have a new BMW drivers seat foam I need to install. Just replaced calipers and did the rotors/ pads..new throttle body
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  #100  
Old 02-28-2020, 08:09 AM
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ucsbwsr ucsbwsr is offline
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Location: San Diego
 
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Mein Auto: E61
Quote:
Originally Posted by 0-60Motorsports View Post
Black would look more "Vader"
True but deep inside Vader is a soft old man at heart and loves some beige on his booty.
Quote:
Originally Posted by cjhansen View Post
Love the work you've done! How's the budget bushing/ control arm kityou installed holding up?
So far just fine but I am not putting many miles on this thing.
Quote:
Originally Posted by CurlyTopRob View Post
Very Niiice!!! I got an e39 last year and am currently working on it. This was/is a nice build. Any updates on it since the last post?
Lot's of good stuff is about to happen. Manual swap, M5 steering box, Vanos, timing chains, Zionsville cooling system, etc.

I plan on filming the rest of the build too.

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N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Swap, MFactory SMFW, Spec Stg 3+ Clutch, Shiftteck SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Ethanol Sensor
- N54B30, JB4, Hexon RR550s, Custom Y-Pipe Inlet, AR DPs, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB PCV, BMS OCC

E39 540iT:
- OEM Style 167, KW V1
- E38 Contour Seats
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