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

[1st 5er]

Very nicely done Roy.

[5280 JB]

Just beautiful, Roy!

[MicahO]

Gorgeous - looking forward to seeing it again soon!

[wkohler]

Wow. Looks great. Kinda bummed I didn't take you up on those wheels! Haha.

[RoyW]

Wow. Looks great. Kinda bummed I didn't take you up on those wheels! Haha.

Thanks all for the nice compliments.

Chris... Glad you didn't, as I''ve now had those wheels for 16 years and on 3 different cars

RoyW

[Leo F.]

That car looks like a lot of fun. Very cool!

[BimmerSultan]

Don't take this the wrong way, but I hate you. I mean genuine, down-home, good ol' southern boy type of hate you.

[Chimi-Changa]

Great pics- that second to last one though....So nice, like it plopped right down from Heaven

[Motronic]

Nice job Roy!!

Are you bringing that car to Saratoga or Larz this summer?

[RoyW]

I haven't provided any update on the 535 project car in quite awhile (since May?) and, admittedly, we didn't do much right after The Vintage.... what with vacations, Summer, my mechanic friend Steve being out of the country, etc., etc.... but, she's nearly completed, with only a few small remaining items left to do.

Here's a summary of the work completed over the past few months and those few remaining gnats that I hope to complete this Fall ... just in time to put her away for the Winter I'll be looking forward to driving her next Spring and shaking out any newly discovered gremlins

- completed stereo system install (however discovered issue with the 4 channel amp, specifically, the rear right channel doesn't function). Will resolve this in the Fall or Winter
- installed UUC duel-selector rod (original one they sent with the short-shift kit was the wrong length)
- bled clutch and adjusted clutch pedal stop
- had full valve adjustment done (when having the car (MegaSquirt) dyno and tuned by Peter Florance in May, it was discovered that the engine vacuum reading was too low, and he suspected a valve adjustment issue.) Valves were indeed tight and valve adjustments were made... now she runs very smooth and fast
- wired up fog lights. Resolved check panel lights issue cause by bad ground and connector/wire on the rear taillights
- hooked up washer nozzles and hoses. Installed new battery hold-down hardware
- removed and re-aligned the Hartge front valance and the front bumper (needed a 1/4" more room to get turn signal lens and trim piece in under the bumper). All's good now

There are still a few remaining issues, but I expect to have them all addressed in the coming couple of months, these include:

- installation of edge protection seals on door frames (pinch welds) when available/obtained?
- resolve non-working tachometer issue... may be a MegaSquirt box issue or bad tach in cluster?
- install boost and air/fuel gauges in the ashtray area
- obtain and install couple of small & misc. pieces, etc. in the interior

It has been a fun almost two years on this project and the car came out almost exactly as I envisioned it... but, naturally it took about 6 months longer than expected, as it's the little things that either delay things or at least slow you down My personal thanks to Steve, Brad, Ian, Todd, Peter, Jerry and the VSR team for their great contributions to Project Sepang... and, of course to the many here who sold or gave me parts that are now part of this car... specifically, Ted, Eddie, Randy, Dana, Aaron, Chris, Ray, Mike, Jim, and a few I'm sure I've forgotten. You guys are the best!!!

Now, to enjoy the car (and little this fall, but really starting next Spring) for a couple years and then... who knows Here are a few pictures of some of the work referenced above.

-RoyW

[Coldswede]

I love this car so much. I had to surreptitiously wipe a bit of drool off of it a few times at The Vintage last Spring.

[bkbimmer]

Another nice car in your shed.

[GaAlpinaOwner]

Roy that is one sweet lookin custom E28 sir!

All the best,

David Frankel

[fastcrs]

Such a stunning car...I can never get tired of looking at it...

[trevmmeister]

and then... who knows

I call dibs.

As quoted from the Code of Bros, Article 62;

"the Bro who calls dibs first has dibs."

[Coldswede]

and then... who knows

I call dibs.

As quoted from the Code of Bros, Article 62;

"the Bro who calls dibs first has dibs."

Sorry but your "dibs" is about number 1001! Folks were calling dibs before the car was ever done. I know cuz ... .

[trevmmeister]

Damn. I'll get lucky one day..

[RoyW]

When its time to go, you'll all get a shot!

-RoyW

[GaAlpinaOwner]

Roy enjoy this car for a while. It is all you buddy!

[FedExguy]

Wow. It's 2am and just went through the entire thread. Wow. Any chance you'll be at Show and Shine this weekend?

Thanks for the great pics.

WOW

RJ

[RoyW]

Did a little work on the car yesterday, as my friend Steve came over, so we knocked off a couple more items on the to-do list, including:

- resolved the "no tach" issue. Turns out it was a problem in the MegaSquirt box... I had sent it to Peter Florance a few weeks earlier for a check-out and he found the issue was there and repaired it. Received a couple clusters to test with, but turns out it wasn't that, so back they go Thanks guys.

- wired in and tested a Boost gauge, so now we have both Air/Fuel and Boost gauges that both work. We'll put them in the ashtray location in the center console... my friend Ian is making a gauge pod that will fit in that space. Hope to have it in place for pictures later this month

- put in new adjustable clutch stop

- discovered the seat belt receptacles (M5 front sport seats) don't work with 535 seat belts (different cut-out on the metal end of the seat belt latch). Looking for 535 receptacles to attach to the front seats in place of those M5 ones

- took measurements for custom muffler & piping fitment, as I plan to replace the new SS exhaust that's currently installed with a straight 3" set-up from the downpipe back... looking at Magnaflow or Borla stainless steel mufflers that will fit in the muffler opening of an e28 More to come.

Sorry no picture, as there was nothing really picture-worthy in these few accomplishments.

-RoyW

[wkohler]

Roy, you should just get later seatbelts up front. The likelihood of finding the sport seat receptacle for the earlier belts is pretty low. They weren't very common.

[trevmmeister]

Any updates to ring in the New Year?

Nice Roy! I hope you enjoy the project.

You just know if Roy builds a car it is going to turn out two steps beyond perfect! I've yet to see one of his cars I'd not sell a kidney to buy!

It's gonna be drool worthy!

[RoyW]

Any updates to ring in the New Year?

Thanks for asking... in fact I have done a couple things lately and have a few others in the plans (seems like "project cars" are never done?), as follows:

- I did get the seat belt issue resolved (mis-matched belts clips with the receptacles on sport seats) by sourcing a set of later model 535 belts that work with the sport seat receptacles

- I had a right rear channel in the stereo system that wasn't working... so, I needed to get that Soundstream amp repaired (its at the shop now), but after removing one SS amp, I decided to remove both of them and install a single JL Audio 5-channel amp that I had (from my previously owned M635). All checked out great after the swap. I'm also having a custom sub box built to house a pair of 10" subs. That box will fit right in front of the amp board, between the wheel wells (low and long)

- I also had decided to change the exhaust system to allow for more air flow (this was advised by Peter Florance after the dyno last spring) since it was being squeezed down a bit from the 3" downpipe to the twin 2 1/2" pipes going into the Supersprint exhaust system via the custom "Y" pipe". So, I removed the Supersprint exhaust system (sold it to a fellow Board member) and plan to install a semi-custom 3" exhaust system using something like a stainless 3" Magnaflow or Sterbo muffler (and maybe resonator) with the necessary custom stainless pipes, hangers, and dual Vibrant tips needed to complete the install. This will be a Springtime installation task, once I decide on and get all the necessary parts.

- Will need another tuning of the Megsquirt system once the new 3" exhaust system is completed... so, another visit to/by Peter will be in order in the Spring

- A friend is currently building a two-gauge pod (boost & fuel pressure) that will get installed in the front console ashtray space

- still a few other minor trim items need to be sourced and installed... hope to have those by Spring too.

Here are a few pictures of the amp swap and the removal of the SS exhaust system.

-RoyW

[trevmmeister]

Very nice. Looks like 2015 is the year, huh! Would love to hear that thing run, as I have personally never. Mind posting a video if you can find the time?

[RoyW]

Very nice. Looks like 2015 is the year, huh! Would love to hear that thing run, as I have personally never. Mind posting a video if you can find the time?

Be glad to post a video once the new 3" exhaust system is in....hopefully in April

-RoyW

[bkbimmer]

I love your car, sir.

The black jam area's are kind of depressing though considering how nice the rest of the car looks. Just picking at nits though.

[Dinan e28]

Its about time ...car was junk without that $6 part

[tig]

I just re-read this entire thread. You did such a balanced, tasteful job with this car. I am collecting a list of builds to use as inspiration for my new project and Project Sepang is at the top of the list.

[RoyW]

It's been a while since I've posted any update on the Project Sepang car, as things generally went in to hold-mode over the Fall and Winter... since, I've been awaiting parts; been busy with many other things, especially detailing customer cars this Spring; and my ace-mechanic friend, Steve's availability was limited. I did, however, get a few things re-done that I wasn't happy with earlier this Spring:

(1) replaced the 2 1/2" Supersprint exhaust system (that we took out last Fall) with a custom 3" system (SS pipes, Flowmaster resonator, muffler & tip) up at Vintage Sports & Restoration. I'm not crazy about the exhaust tip and may look to find something I like better... been searching the 100's at Summit Racing, but haven't found the right one yet ;
(2) I had the front seats re-covered, as my dye-job wasn't to my satisfaction;
(3) We also replace the stock external fuel pump with a Welbro 255, as the in-tank Welbo is way too loud and will be replaced with a new stock lift pump.

Anyway, this past weekend we spent most of Saturday buttoning up a few things:

- installed seat belts to match receptacles on these M5 sport seats;
- installed re-covered front sport seats (I need to find another beige seat back cover, as one of the two that I have and installed is from an e30 and has the cut-out for the seat back forward handle);
- installed used edge protection seals (still awaiting new ones that have been on back order now for 15 months)
- installed front & rear sill plates (my rears were both badly cracked, so since these parts are NLA, I order front ones, which are still available, and cut them to size )
- vacated and charged the A/C system. .. no leaks and she blows cold
- then, we actually went for a drive But, just when you think things are done or almost done with a Project car, the devil jumps up and bites you in the ass. During our drive we heard a noise coming from the rear, I commented, "that doesn't sound good" and started to pull over when the diff locked-up (both wheels skidding along). Fortunately, we were at low speed when this happened and getting to the side of the road was no issue. Long story short, went and got the trailer, winched it into the trailer (after Steve un-bolted the half-shafts from the wheels so it would roll), and up to his shop it went... where he discovered the nose bearing/pinon gear was shot. It will be re-built this week, I think.

So, here are some pictures of activities on the car since my last update, mostly from this past Saturday.

-RoyW