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

[Motronic]

Nicely done Roy!

[Coldswede]

Nicer work Roy, the Sepang looks great. I am glad to hear even the great ones among us have those "Oops" moments.


I am in lust with this car

[T_C_D]

Awesome car/build but what the heck is going on with the air filter?

[RoyW]

Awesome car/build but what the heck is going on with the air filter?

Just turned the K&N filter/tube up (from it cozy little corner) in order to do the A/C system service

-RoyW

[stuartinmn]

Looks nice, too bad about the diff.

- installed used edge protection seals (still awaiting new ones that have been on back order now for 15 months)

Good luck with that...I've had a set on back order for about six years now.

[wkohler]

That seems to be about the lead time for Euro E12 fenders. I think you will all get your new seals before I get fenders.

[RoyW]

What, no comments on the oval exhaust tip? I was hoping for a couple ideas or thumbs up if OK, or thumbs down if "not-so-much". I think its a little to big (tall), but width-wise it fills the cut-out in the rear valance nicely. Unfortunately the dual tips I've look at either don't fit or look crappy... so I went with oval like I had in the B7. I also don't like the edge of the inside 3" pipe showing, should be smooth, and not visible transitions, I think? So, for now, it stays.

As for the edge protection seals, I know they have been out-of-stock for years, but BMW logistics says they are making a batch... have been for 12 + months now, as I get a Ground Hog Day email string from local BMW dealer parts to BMWNA logistics to BMWAG logistics about once a quarter I'll be sure to let you know if it ever happens.

-RoyW

[wkohler]

I wonder if I could ask them where in the hell my fenders are.

[Das_Prachtstrasse]

I'm not a fan of that exhaust tip. I think a Hartge one would suit it better if you wanted that ovalish shape.

[Stevo12]

What, no comments on the oval exhaust tip? I was hoping for a couple ideas or thumbs up if OK, or thumbs down if "not-so-much". I think its a little to big (tall), but width-wise it fills the cut-out in the rear valance nicely. Unfortunately the dual tips I've look at either don't fit or look crappy... so I went with oval like I had in the B7. I also don't like the edge of the inside 3" pipe showing, should be smooth, and not visible transitions, I think? So, for now, it stays.

Fine, if you don't mind me saying...

I think you should bring back the dual tips, providing you find some that fit the 'groove' of the build. I quite like the Borla "intercooled" tips that are on my car. Very period-chic.

Hope those seals worked out well for you!

[davintosh]

I love everything you're doing with this car, Roy! It's awesome in photos, and even better in person.

I wonder though if I'm the only one who can't help but think of The Knights Who Until Recently Said "NI!" when I see the title of the thread.

[stuartinmn]

We are no longer the Knights Who Say Ni. We are now the Knights Who Say Ekki-Ekki-Ekki-Ekki-PTANG. Zoom-Boing. Z'nourrwringmm.

[CSBM5]

What, no comments on the oval exhaust tip? I was hoping for a couple ideas or thumbs up if OK, or thumbs down if "not-so-much". I think its a little to big (tall), but width-wise it fills the cut-out in the rear valance nicely. Unfortunately the dual tips I've look at either don't fit or look crappy... so I went with oval like I had in the B7. I also don't like the edge of the inside 3" pipe showing, should be smooth, and not visible transitions, I think? So, for now, it stays.

I actually think the tip looks ok. At first glance my thought was ugh, oval; should have just gone with a single round tip perhaps. Upon reflection and seeing how well it fits the opening, I came around to like it.

Nice job on the rest of the exhaust also. My old engineer part (fluid dynamics) had issues when it saw that original 1-into-2 transition. It would be a lengthy thought process and text to describe, so suffice it to say my gut did not like the design of that transition -- too much pressure drop likely required in that transition design, but of course you are limited in length to get into that stock 2-pipe (or Supersprint, whatever it was) setup too. The new setup would appear to be a much more beneficial design.

Beautiful car!

Regards,
Chuck

[RoyW]

Well, at long last, it's done (I think?) Over the past few weeks we put the finishing touches on the car and completed everything that was left on the punch list... so the two and a half year "build" of Project Sepang comes to a close. The items completed these past few weeks include:

- gave up on getting new edge protection door frame gaskets, which I had had on order from BMW for the past 15 months, and pick up a very good set of used ones from Todd, thanks TCD , and installed them.
- installed the rear speed sensor which were missing on this car (didn't notice that until the ABS light wouldn't go off). First set I ordered were the wrong ones, i.e., didn't fit... second time was a charm
- resolved brake lining warning light on check panel
- swapped differentials from the 2.93 LS I had gotten from TCD Todd when the original locked up a month or so ago, and swapped in a 3.25 LS that I got from a member in Canada ... thanks to Squirrely for bringing it down from TedFest
- removed exhaust tip and replaced it with another who's shape I preferred (still not perfect)
- installed Racing Dynamics front shock tower brace
- had Peter Florance fly on up to again dyno-tune the MagaSquirt system/engine, because the exhaust had been changed from a blended 3" and 2 1/2" to a full 3" system, and the valves had been adjusted since the initial tune he did in May 2014
- Tune is right-on, idles beautifully and runs terrific. Dyno results were a little lower than expected, as it was 93 degrees with 85% humidity the day we did it, but still had 268 bhp at the wheels and torque was a little under 300 lbs/ft. Cooler weather and an e-brake that now isn't dragging due to issue with handle and release button (was when we dyno'ed but didn't notice until after ... now we know what the smell was )
- had a wheel alignment done and re-balanced front wheels
- had a MA State inspection and got my sticker
- went for a 2 hour drive (today)... glorious!!!

Again, thanks to my friend and ace-mechanic Steve for all the help along the way.... as well as those others that contributed with wrenching, parts, consultation & advice, etc.... couldn't have done it without you

Thoroughly enjoyed this project and would gladly do another, but as this is my third in 10+ years, I think I'll take a break

-RoyW



Great set of edge protection door frame gaskets



New rear speed sensors

removing 2.93 diff


Cleaned-up, painted, & installed 3.25 diff


removing oval exhaust tip


new rectangular exhaust tip installed

strut bar installed

[athayer187]

As always, very nice!

[tig]

Thoroughly enjoyed this project and would gladly do another, but as this is my third in 10+ years

Seems like about the right pace, to me. I've been slowly ramping up to this level of build since 2006 when I started doing stuff myself with my FJ40. Vlad's near done and it was more of a transmorgification than a build. The blue car will be my first real "ground up" build. I'm projecting 2 years and am dreaming it comes out close to as nice as Sepang did.

[leadphut]

Well, at long last, it's done (I think?)

"Art is never finished, only abandoned" ~ Leonardo da Vinci

"fugeddaboutit. that's a nice cah!" ~ Leonard "da Pimp" Ramano

"Love your car Roy!" ~ leadphut

[Thatguy087]

This car is amazing! Flawless

[Adam W in MN]

Nice conclusion Roy!

[oldskool]

Next chapter please. . .

[Coldswede]

Such a gorgeous car Roy! I love the thing.

Great build log too.

[86GT635]

Super clean! Hopefully see it at the vintage next year? Maybe with a different exhaust tip..

[alpinamotorsport]

1:16 am and I just finished the whole thread. wow! unreal!

[T_C_D]

Roy,

I am glad you are happy with the car! I didn't know you were going to run the lowest boost level TCD car ever! Sorry i sold you the 292LSD.

Todd

[bkbimmer]

Beautiful car, that tip was horrid.

[mescko]

I didn't mind the oval tip, tho' I like the rectagular better. I wonder if I'm the only one that thinks color-matched wheel centres would be the perfect final touch...

[Zengineer]

Awesome build, very inspiring. I like the custom touches a lot, while still retaining what makes these cars so great.

[RoyW]

As said by others, "you're really never done with a project car"! So, over the last couple weeks a few additions or changes were made to the 535... and, I will no longer say "its done" or has reached the "final chapter" In addition, Project Sepang may make an appearance in a well-known and great publication sometime in the near future? Spent the better part of a day last week showing, talking about, doing some driving, and in a photo session with said publication's Editor and Associate Editor

Specifically, the following was completed in the last two weeks:

- My friend, Ian, fabricated and installed the boost and air/fuel mix gauges into the ashtray area of the center console
- As the performance with the turbo system was at pretty low boost level, e.g., 5.9 lbs, yielding 260+ wheel hp... with Ian's help, we swapped in a 10 lbs. spring, provided by TCD (in place of the 6 lbs. one) . Holy crap what a difference... much faster and pulls like a train!! Todd says we should now be north of 325 wheel hp and 340 torque. I will get her back on the dyno to get the actual performance numbers later this month and see what the data log says
- Also, a few other minor tweaks to the sound system, cleaned up some wiring, adjusted the exhaust tip, etc., etc.
- Pics below

Still need to do some work on the sunroof's operation and the driver's seat operation (not all functions working properly), but those will be Winter tasks. I'm sure a few more things will crop up and need fixin' too (as I put some real miles on the car in the next couple months), or some other mods or changes are made as I continue to "personalize" this custom example... we'll see.

-RoyW


Gauge pod fab'ed


Gauge pod installed


6 lbs waste gate spring removed after inter-cooler and a few hoses dis-connected and moved aside

Unfortunately my picture of the 10 lbs spring didn't come out, but it was much bigger in diameter and thicker (and red)... it was a bitch to push the cap down and align the holes so the bolts could be started and tighten.. couldn't take a picture of that procedure, as while Ian was doing the muscle work of compressing the spring and holding/aligning the cap down, I was turning in the bolts... not a lot of room for 3 hands in there!


HS&EC Assoc. Editor & Photographer photo session

[5280 JB]

Congrats Roy! I'll look forward to seeing a familiar face (grille) in my mailbox when said future edition of HS&E arrives

Jim

[RoyW]

Finished up the final few items on the car today, as my friend Steve came over to lead the effort. I think I can finally say that she is finished... just maintenance going forward... no plans for any other mods/changes and nothing else needs repair Here's what we did today:

- driver's seat wasn't working at one of the 4 adjusting function switches, e.g., rear of seat wouldn't go up/down to adjust that height. Took the seat out of the car and apart to test where the problem was... turned out to be one of the gear thingies was jammed up... got it turning freely and put that marvel of engineering back together (see picture below). Glad Steve knew what he was doing, because I would have been clueless

- sunroof wasn't working at all (had before)... took that trim piece off at front of headliner by the switch and found the wire/connector had mysteriously come apart. Put it all back to together and now the sunroof works perfectly

- address interior lights not all working properly... all's now good

- a had a low oil check light on the panel all the time (oil level was good)... so, replaced the oil level sending unit. No more light

- went for a long drive... probably the last of the season, as being able to do so on December 5th in New England is a bonus. We've had no snow to date, so no sand or salt on the roads and the temps have been quite mild... it was in the mid-40's today... the car/turbo loved it Then I filled her up, added Stabil, took a few pictures in front of a vacant Priory in my town, washed the car, parked her in the Bahn, put tire pressures at 47 psi, disconnected battery negative, and covered her up... awaiting next Spring!

I heard from Hemmings Sports & Exotic Car magazine last week that Project Sepang will get a small feature in their next issue

Here's a few pics from today

-RoyW