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Camaro69Z28
12-24-2004, 03:22 AM
One of europe fastest bmw 5 series.
Hardcore engine brakes and chassis

Engine spec

The engine is almost (so far) "untouched", exept "sport" camshafts from Catcams (Belgium) and of course the ESS supercharger-kit. Until March 2002 I used a Powerdyne charger (BD-11A), It has worked just fine but it had to go this spring due do the "stage III"-project, the Powerdyne can't deliver the boost I need.

so what is "stage-III"?


ESS Superchargerkit "Stage 2, 108-83x"
Bigger Intercooler
Even larger Injectors
More boost ~10,0 psi
Camshafts (Catcams "sport" stage II)
Twin Bosch dumpvalves
ESS reprogrammed ECU
Polished Aluminum 3" pipes with silicone hoses
Full flow sport catalysts
Ok but was there ever a stage II?
ESS Superchargerkit 108-80x Powerdyne
More boost, ~7,2 psi
2x2.5" stainless race exthaust system (with no cat's)
ESS reprogrammed ECU
Well then what the heck was stage I?
The "stage I" was actually my old car, an 540iA (E34) also equipped with an ESS supercharger kit
Is there a stage IV?
If you asked me ½ a year ago there was no stage IV - but suddenly a thought was formed in my mind - and voila; stage IV is born:-), it includes competition headers, and fully ported heads, 3'angle vent-seats, mabye a slight raise in boost to 12 psi plus an Aquamist system to insure safe running under all conditions, twin M5 fuelpumps in a "E32-750" arrangment, psyco-large single aluminum dump-valve and of course a new ECU mapping.
Goal is 550+HP

Progress update - stage IV

2004.01.08 - Custom 102mm MAF
2004.01.11 - Plasma Coils
2004.02.15 - Stage III Heads confirmed from VAC, stripped and ready for port/polish and buildup with new components - will be ready by early March
2004.02.25 - New "HiPerf" Intercooler confirmed from Alutech, core ordered from thier supplier



More details


Sport camshafts from CatCams in Belgium



partnr
[email protected]
[email protected]
max.lift (mm)
lift@TDC (mm)
clearance (mm)

[email protected]"
[email protected]"
max. lift (inch)
lift@TDC (inch)
clearance (inch)

peak angle
followers
springs
retainers
infolink


1303704
268° - 268°
24/64 - 64/24
10.90 - 10.90
1.40 - 1.40
hydro

222° - 222°
1/41 - 41/ 1
0.429 - 0.429
0.055 - 0.055
hydro

110° - 110°
STD
STD
STD


Stage V Diary

On this page you can "in-detail" follow the Stage V project

2004-12-22, Started a discussion with Tony at VAC Motorsports about custom intake with 8 separate throttle bodies and custom plenum(s), the sleeves has arrived, but I decided to let Tony do some additional machining on them on his advice, this will simplify things when the final work is being done here in Sweden.

2004-12-16, Went up to Patrik and Alutech this morning with the Rotrex additional parts, discussed how to solve the intercooler problem with a descent symmetrical piping, at least same capacity as the current one, good flow values etc... I think we came up with a resonable solution - I've seen nohting like it on any S/C'ed car out there today, more info as soon as I have something to show!

2004-12-14, The Rotrex parts came up with DHL Today, quite funny they used a Setrab oilcooler (a Swedish brand)

2004-12-14, Tony from VAC got back to me today, the sleeves are supposed to be at VAC at the end of the week

2004-12-13, Just found out from Rotrex that the SP30-94 units was not available anymore (replaced by C30-94 with improved internals on the gear-side), problem is they are not available until March.... thats - big problems

2004-12-13, Trying to get hold of the Oilcooler,cannister and filters from Rotrex, supposed to be sent by DHL Thursday last week

2004-12-10, Mailed Tony at VAC Motorsports requested status on my order of the set of flanged steel-sleeves.

2004-12-10, Took the car to Alutech in Gävle this morning, had a 1 hour discussion with Patrik (thanks for the coffee and leverpastej-sandwich!) about my thougts and plans for the installation of the twin Rotrex setup, leaved the car up there to be able to run the Stage-V-project on two fronts. Patrik/Alutech will work on the Rotrex installation togheter with the new intercooler, cooler, oilcooler, piping, relocation of oilfilter, servo-cannister, and 2000 other small issues that has to be solved, I'll get back to the "second "front" next week :-).

btw. a quite intresting drive up there today, the car has been in the garage since SCF, and when going 07.30 am, I realized that water for the wipers had'nt been installed since the paintjob. Took a few stops on the 150km's drive to clean up the windshield to get some visibiltiy, also the grip in the Yokahamas AVS 315/20-19" simply is not the "optimal" for winter conditions....

2004-12-10, Official start for Stage V




Chassie, driveline and brake modifications

The orginal M-tech chassie have been upgraded during 2002 and even further this year.

Current upgrades

Front-end upgraded to M5-type (from an 00' with 4000km'rs), including the better version of Servotronic from M5, hubs etc..
Rear-end upgraded to M5-type (from the same 00' above), including the special M5 stabilizers, hubs etc..
Eibach springs, old type for M5 (ProKit)
Eibach Anti-rollbar kit, for M5
Koni sport adjustable shock absorbers
Brembo Gran Turismo (F50) kit; 380/36mm-8 piston front and 345/36mm-4 piston rear
M5 LSD (3.15:1) adjusted to approx. 40% lockup.
M5 Driveshaft and halfshafts.
Sachs Race Engineering Clutch - 240mm pressureplate with an "special-organic" disc, takes 640Nm, and withstands about 2 times higher tempratures that an standard disc.
VAC Motorsport's Lightweight Aluminium Flywheel (13 lbs)
Wiescher's sport strut-bars in polished aluminium, front and rear.
BeastPower rear swaybar brackets.
Progress update - stage IV

2003.11.20 - Polyurethan bushings from Powerflex
2004.01.05 - KW Inoxline type III - fully adjustable coilovers

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Souncheck (http://www1.540is.com/soundcheck_february.wmv)
Dynorun stage 3 (http://www1.540is.com/540is_dynoplus.wmv) Stage 3 test (http://www1.540is.com/540is_3.wmv)
Rorberg meet (http://www1.540is.com/Rorberg_540is_clips.wmv)
Supercharged bwm 540 is (http://www.540is.com/)

Jagarang
12-24-2004, 08:20 AM
These pics a GINORMOUS!! It's like dial-up pergatory...OUCH! Thank goodness I've got DSL.

Camaro69Z28
12-24-2004, 08:47 AM
I wonder how long the current stock gearbox last under all that power and torque.
:git: :revto9k: :headbang:

JamesJ
12-24-2004, 10:14 AM
I cant even see what I am looking at.

Bill Howell
12-24-2004, 10:30 AM
I am such a sucker for german iron.They drive so well.
Great video! Not sure I want to ride shotgun on those narrow roads though. I'm guessing they all get narrow at those speeds!!
Thanks for sharing,

TonyL
12-24-2004, 11:28 AM
pics now resized.

Not bad. 350 kw is 476 hp. He's almost to his 500+ goal.

never heard a beemer sound like that before!

B Cichocki
12-24-2004, 12:39 PM
Gawd, I loooove BMWs. I've got a 540i, two euro 745i's and a euro M6. They're such nice cars, and (for the most part) they're built like tanks. The 745's handle so flat at speed it's incredible. They've got turbocharged i6 engines and the cars don't even feel happy until you're above 85 mph- then they pull like nobody's business. Autobahn designed machines for sure.

And let's not even get started with the new M5. A 500 horse V10 that revs to the moon backed up by a 7-speed sequential gearbox. I really want one, but that ain't gonna be happening. :crying:

In any event, thanks for posting that. A badass bimmer for sure. The M3 wheels look pretty sharp on there as well.

-Brian

Camaro69Z28
12-25-2004, 02:55 AM
This monster of faster than the new e60 m5 .
When it's fully tuned.
And it tuned in a pro touring style!!
This would be a cool engine in a pro touring car.
:git: :yeah: :angel: