535i "Project Sepang" build -08/05/18 update

[RoyW]

I finished up a few things this week getting ready for the trip to PFTuning in VA (Wed/Thurs) and then on to The Vintage (Fri/Sat) this coming week. The car is/will be 95% complete cosmetically and about 90% mechanically. Here's what was finished this week:

- exhaust completed
- turn signals wired in
- sunroof mostly adjusted (still needs work)
- seats bolted down (what a PITA when things don't line up or were x-threaded... had to chase three holes and tap one)
- wipers and washer nozzles installed
- misc interior items
- car detailed ( compounded, polished, glazed, waxed, etc.)

Here's what's left to do on the way to and after Vintage:

- MegaSquirt tuning and dyno
- fix whatever the tuning data dump shows to be a problem(s), if any. Then, shake down period of driving (I'm sure there will be issues to deal with, as it currently runs lumpy and rich, with very poor idle)
- install new tranny sector rod
- complete stereo system install
- fix driver's door trim piece at bottom of window
- figure out why one rear headrest won't go down all the way?
- wire driving lights and make turns signal lights function as parking light as well
- install gauge pod and gauges
- adjust center of Hartge valance down 1/8" so coverings pieces (inside the driving lights covering bolts) will fit properly
- few other smaller interior items

I took some more pics today after the detailing, figuring this is the best its ever going to look... and yes, I plan to drive this one

-RoyW

[Adam W in MN]

That may be the most perfect ride height I've seen on an E28. The wheels weren't my thing at first, but they're growing on me.

Will be very interested to hear about the power and driving experience once it's 99.9% tuned!

[Das_Prachtstrasse]

Stunning.

[trevmmeister]

The most gorgeous piece of art that I have ever seen. Roy... please, don't get rear ended.

[leadphut]

[Dinan e28]

the Hartge spoiler was a must with the rear and side skirts.

One more thing for the list, don't forget the black plastic trim between the fogs and the licance plate.

It took me years to order that $6 part.

She is looking amazing.

[RoyW]

the Hartge spoiler was a must with the rear and side skirts.

One more thing for the list, don't forget the black plastic trim between the fogs and the licance plate.

It took me years to order that $6 part.

She is looking amazing.

They're on order.

-RoyW

P.S. and, Thanks to all for the nice compliments

[cddallara]

That may be the most perfect ride height I've seen on an E28. The wheels weren't my thing at first, but they're growing on me.

Will be very interested to hear about the power and driving experience once it's 99.9% tuned!

This

[m-racer]

Very pretty. I like the Fikse's, but then I also liked them on your M635.

[jdirty]

Your car looks amazing RoyW! Awesome work.

The wheels weren't my thing at first, but they're growing on me.

That's also how i felt.. now i love everything about the car.

black plastic trim between the fogs and the licance plate.

They're on order.

What is this part # you guys speak of? I'm seeing two different shapes on realoem. One square-like piece(51711888653) and one rectangle piece (51711873623)

[tig]

Roy, can you please espouse on what you used for the firewall insulation seen in this pic? Happy with the results?

Thanks.

[RoyW]

Your car looks amazing RoyW! Awesome work.

The wheels weren't my thing at first, but they're growing on me.

That's also how i felt.. now i love everything about the car.

black plastic trim between the fogs and the licance plate.

They're on order.

What is this part # you guys speak of? I'm seeing two different shapes on realoem. One square-like piece(51711888653) and one rectangle piece (51711873623)

The black trim parts that I have on order are: 1 71 1 888 653 & 654

-RoyW

[RoyW]

Roy, can you please espouse on what you used for the firewall insulation seen in this pic? Happy with the results?

Thanks.

The material I used on the firewall cover is simply sound and vibration deadening stuff like that which I used on the inside of the cabin... it's like Dynamat. That original covering was in bad shape, all cracked and nasty looking and it is an NLA part... so, I just decided to cover it over. Its not ideal, but it looks a lot better than before

-RoyW

[TheE28Ranch]

Pictures don't even do this car justice. It looks outstanding in person. Nothing looked out of order to my layman's eye. Being one of the ten award winners at Vintage with 300+ cars isn't too shabby a showing, either. Nice, Roy.

[RoyW]

Well, the 535 project car made it to The Vintage this past weekend despite not be fully completed or registered (had a plate on it, but out-dated sticker). It was close enough from a mechanical & cosmetic perspective to make that previously set goal to bring it to this event... and, since I needed to have the MegaSquirt system tuned by Peter Florance in VA, I combined the two events, which were only 5 hours apart, into one trip.

The week prior to Vintage, I completed a bunch of small stuff, e.g., antenna delete, trunk trim, wipers, etc. and loaded her into the trailer for the trip South. Had a couple problems on Wednesday on the way to VA, e.g., blow-out on a trailer tire on I-95 (YIKES!) and big traffic delays around NYC, but made it safe and sound to Virginia Beach, after a 13 hour drive, about 3+ hours later than expected.

Met Peter at Abacus Racing for the dyno runs and MS tuning on Thursday morning. All went reasonable well, but we had a low vacuum reading at idle, which after confirming no leaks, was attributed to valve adjustment. Not wanting to burn any valves, we decided to not do any hard runs until the valve clearances could be checked... we'll re-do the dyno hopefully in June. But, Peter was able to get a nice smooth idle and the engine running very nicely with some moderate runs on the dyno and MS tuning work from his laptop... a 100% improvement from its running condition before his work! She sure pulled pretty well around the parking lot He anticipates about 340 lb/ft of torque and 320 bhp, maybe more?

Anyway, had a great time at The Vintage and the car was well received. Later in June, we're hoping to button everything up and get the few remaining tasks completed; get the car registered; and out on the road fro a good shake-down.

Here are few pictures from this past week at the dyno with Peter and at The Vintage.

-RoyW

At Abacus Racing's dyno with Peter F.





At The Hawthorn parking lot, full of vintage BMWs




At Olde Salem Village next to Eddie's brilliant e12 (the 1st Place People's Choice Winner)

[wkohler]

Roy, it came out awesomely. Great work.

[Adam W in MN]

Great pics guys, I've been hoping for some more shots of these two cars, but even better to have these with them side by side.

[Ricky]

This is amazing! It's an inspiration thread for me

[Blue Shadow]

I was happy to see this car at Vintage. The color really pops in real life and Roy has made a very nice driver? really? out of all the parts he had left over. Upgrades all around for a standard e28 and that makes this some kind of ride. Wonder if those two Soundstream amps will have enough power to keep up with the turbo? This build seems to be a very fun car to drive.

[1st 5er]

Speechless, almost.

[Eddie in TO]

Roy,
Project Sepang is an outstanding build. All your time and effort paid off and the result is superb
Seeing this machine last weekend in person was truly a treat and the color is perfect. The way the sun enhances her deep rich color tone is quite intriguing. I can simply pull up a chair and stare at your honey all day long.
Congratulations on an extraordinary and one-of-a-kind masterpiece.
I hope to ride shotgun very soon...

[MicahO]

It was fabulous meeting this car (and especially it's owner!) in person. Inspired planning, inspirational work. I'm looking forward to seeing it soon again as the details continue to get nailed down.

[unt0uchable]

I've got to see this color in real life some time. It looks outstanding on screen and seeing those 2 side by side is really neat!

[GBel]

Roy what everybody else said. I can not wait to see it at Tedfest.

Gary

[RoyW]

Since returning from The Vintage the 535 has seen no real progress on the long list of small items that need to be done to completely finish her up. I did get a few things accomplished, i.e., resolve the rear right headrest issue (it wouldn't go all the way down); put in the trim panel over the radiator; more progress on the stereo system, but, we discovered one of the Soundstream amps was intermittent, so took it to a shop for repair). Oh, and I did get the car plated and registered, and have driven it a little locally! Still another couple sessions worth of work to do... hope to get some of the items done before heading to TedFest, the rest will have to wait until after and my expert help, Steve, is available.

Meanwhile, the Sunday before last a professional photographer friend came over and took some pictures of the car. They came out far better than those I attempt and he promised to come back and take some of the other cars...cool Here's a few of those he sent me.

-RoyW

[trevmmeister]

Those German engineers back in 1988 could only dream of making something so stunningly gorgeous.

[leadphut]

This picture is really nice!

[Thatguy087]

That car is my new favourite e28!

[Drew in NYC]

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Wow, just wow

[GBel]

Drooooling



See you in 3 weeks

Gary