Project Ares: E34 540i/6
#1
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Join Date: Dec 2014
Location: Prescott, Az
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My Ride: E34 540i/6
Model Year: 1995
Engine: M60B40
![Default](https://5series.net/forums/images/icons/icon1.gif)
Hey Guys, here's a little build thread on my E34 540i/6. It's my project daily driver that I've been putting together as a fun hot street build, replacing or modifying along the way as I see fit to my own personal tastes.
I picked up the car non-running. It would crank but not fire.
![Name: BeFunky_20141105_172229jpg.jpg
Views: 1019
Size: 75.8 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152052d1501200874-project-ares-e34-540i-6-befunky_20141105_172229jpg.jpg)
![Name: BeFunky_20141018_0920551jpg.jpg
Views: 790
Size: 123.1 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152053d1501200874-project-ares-e34-540i-6-befunky_20141018_0920551jpg.jpg)
The car came with 18 M-parallel copy wheels. The chrome is destroyed on each, so I dismounted the tires and now the wheels are a coffee table in my apartment.
It took me a while but I found that the harmonic damper was installed clocked incorrectly so the DME was sending fuel and spark timing way off into no mans land. Once it was running I took care of a few leaks and then drove it for a year and a half, slowly modifying things along the way.
I made a grill for it:
![Name: 20150430_191534.jpg
Views: 680
Size: 668.3 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152054d1501200874-project-ares-e34-540i-6-20150430_191534.jpg)
Most BMW enthusiasts hate it, I like it.
Then I traded the wheels off of a junk car that came through my shop.
![Name: 11838671_10200827825733818_5084291996228937629_o.jpg
Views: 1011
Size: 111.1 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152055d1501200874-project-ares-e34-540i-6-11838671_10200827825733818_5084291996228937629_o.jpg)
![Name: 20151112_083130_2.jpg
Views: 915
Size: 188.7 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152056d1501200874-project-ares-e34-540i-6-20151112_083130_2.jpg)
Replaced all of the broke engine & trans mounts for a set of RevShift Poly 95a mounts:
![Name: 20151004_092432.jpg
Views: 609
Size: 681.5 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152057d1501200874-project-ares-e34-540i-6-20151004_092432.jpg)
![Name: 20151004_074312.jpg
Views: 627
Size: 487.8 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152058d1501200874-project-ares-e34-540i-6-20151004_074312.jpg)
![Name: 20151004_092511.jpg
Views: 667
Size: 631.3 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152059d1501200874-project-ares-e34-540i-6-20151004_092511.jpg)
For computer tuning I'm running an Ostrich 2.0 chip emulator installed in a Bosch 404 DME loaded with my own tunes via TunerProRT. I eventually want to get that MAFT-PRO piggyback unit to take primary fueling control as it has wideband O2 AFR tracking capability.
![Name: 20160109_090842.jpg
Views: 692
Size: 518.4 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152060d1501200874-project-ares-e34-540i-6-20160109_090842.jpg)
Installed some seats:
![Name: 12489281_10201285344651505_2652757086259120501_o.jpg
Views: 650
Size: 128.3 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152061d1501200874-project-ares-e34-540i-6-12489281_10201285344651505_2652757086259120501_o.jpg)
After daily driving for 1.5 years it came time to address the clutch, as it was already grabbing at the end of the pedal stroke since day one.
I opt'd to pull the drivetrain, clean things up. Replace & modify a few things.
![Name: 20160308_134119.jpg
Views: 671
Size: 669.2 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152062d1501200874-project-ares-e34-540i-6-20160308_134119.jpg)
I also wanted to dial in some custom cam timing, and add a few bolt on's while it was out:
![Name: IMG_3705.jpg
Views: 620
Size: 518.0 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152063d1501200874-project-ares-e34-540i-6-img_3705.jpg)
![Name: IMG_3721.jpg
Views: 648
Size: 683.5 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152064d1501200874-project-ares-e34-540i-6-img_3721.jpg)
The OE cam timing uses a 246°/242° duration on a 109°ICL with 108°LSA. I advanced intake cams and retarded exhaust cams for a 106°ICL./106°LSA. Nothing drastic, just a little increase in dynamic compression and valve overlap.
![Name: IMG_3741.jpg
Views: 633
Size: 656.0 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152065d1501200874-project-ares-e34-540i-6-img_3741.jpg)
Spec lightweight single mass flywheel, Spec StageII kevlar clutch:
![Name: IMG_3959.jpg
Views: 664
Size: 695.8 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152066d1501200874-project-ares-e34-540i-6-img_3959.jpg)
![Name: IMG_3967.jpg
Views: 639
Size: 600.6 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152067d1501200874-project-ares-e34-540i-6-img_3967.jpg)
![Name: IMG_3955.jpg
Views: 708
Size: 786.4 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152068d1501200874-project-ares-e34-540i-6-img_3955.jpg)
![Name: IMG_4017.jpg
Views: 761
Size: 622.7 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152069d1501200874-project-ares-e34-540i-6-img_4017.jpg)
Cleaned up and painted the engine bay/body/frame. Removed ABS pump, installed manual brake bias valve. Removed leaking 540i steering gear, installed 525i steering gear converter to manual steering.
![Name: IMG_4003.jpg
Views: 711
Size: 692.8 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152070d1501200874-project-ares-e34-540i-6-img_4003.jpg)
![Name: IMG_4046.jpg
Views: 648
Size: 733.8 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152071d1501200874-project-ares-e34-540i-6-img_4046.jpg)
On the way in those aftermarket headers didn't come close to sitting in the body of the car. So the OE manifolds went back on, after a header wrap treatment.
![Name: IMG_4047.jpg
Views: 724
Size: 757.6 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152072d1501200874-project-ares-e34-540i-6-img_4047.jpg)
![Name: 2016-07-30%2011.27.55.jpg
Views: 647
Size: 243.0 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152073d1501200874-project-ares-e34-540i-6-2016-07-30%252011.27.55.jpg)
I then tackled the control arms, and then also lowered the front end a bit.
![Name: 20160731_192134.jpg
Views: 646
Size: 216.6 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152074d1501200874-project-ares-e34-540i-6-20160731_192134.jpg)
![Name: 20160801_101550.jpg
Views: 644
Size: 245.0 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152075d1501200874-project-ares-e34-540i-6-20160801_101550.jpg)
![Name: 2016-08-02%2020.45.01.jpg
Views: 668
Size: 234.6 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152076d1501200874-project-ares-e34-540i-6-2016-08-02%252020.45.01.jpg)
![Name: 2016-08-01%2015.08.49.jpg
Views: 675
Size: 202.0 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152077d1501200874-project-ares-e34-540i-6-2016-08-01%252015.08.49.jpg)
It's going in for an alignment and to have new exhaust pipes made this week. I'll keep modifying it, and tweaking it. The computer tuning and speed density conversion will take a bit. I have toyed with idea of adding nitrous. But really, the only other major mod I have planned is to rid of the 2.91:1 open rear differential and rebuild it using E46 M3 210mm 3.64:1 gears and limited slip carrier.
I picked up the car non-running. It would crank but not fire.
![Name: BeFunky_20141105_172229jpg.jpg
Views: 1019
Size: 75.8 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152052d1501200874-project-ares-e34-540i-6-befunky_20141105_172229jpg.jpg)
![Name: BeFunky_20141018_0920551jpg.jpg
Views: 790
Size: 123.1 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152053d1501200874-project-ares-e34-540i-6-befunky_20141018_0920551jpg.jpg)
The car came with 18 M-parallel copy wheels. The chrome is destroyed on each, so I dismounted the tires and now the wheels are a coffee table in my apartment.
It took me a while but I found that the harmonic damper was installed clocked incorrectly so the DME was sending fuel and spark timing way off into no mans land. Once it was running I took care of a few leaks and then drove it for a year and a half, slowly modifying things along the way.
I made a grill for it:
![Name: 20150430_191534.jpg
Views: 680
Size: 668.3 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152054d1501200874-project-ares-e34-540i-6-20150430_191534.jpg)
Most BMW enthusiasts hate it, I like it.
Then I traded the wheels off of a junk car that came through my shop.
![Name: 11838671_10200827825733818_5084291996228937629_o.jpg
Views: 1011
Size: 111.1 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152055d1501200874-project-ares-e34-540i-6-11838671_10200827825733818_5084291996228937629_o.jpg)
![Name: 20151112_083130_2.jpg
Views: 915
Size: 188.7 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152056d1501200874-project-ares-e34-540i-6-20151112_083130_2.jpg)
Replaced all of the broke engine & trans mounts for a set of RevShift Poly 95a mounts:
![Name: 20151004_092432.jpg
Views: 609
Size: 681.5 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152057d1501200874-project-ares-e34-540i-6-20151004_092432.jpg)
![Name: 20151004_074312.jpg
Views: 627
Size: 487.8 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152058d1501200874-project-ares-e34-540i-6-20151004_074312.jpg)
![Name: 20151004_092511.jpg
Views: 667
Size: 631.3 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152059d1501200874-project-ares-e34-540i-6-20151004_092511.jpg)
For computer tuning I'm running an Ostrich 2.0 chip emulator installed in a Bosch 404 DME loaded with my own tunes via TunerProRT. I eventually want to get that MAFT-PRO piggyback unit to take primary fueling control as it has wideband O2 AFR tracking capability.
![Name: 20160109_090842.jpg
Views: 692
Size: 518.4 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152060d1501200874-project-ares-e34-540i-6-20160109_090842.jpg)
Installed some seats:
![Name: 12489281_10201285344651505_2652757086259120501_o.jpg
Views: 650
Size: 128.3 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152061d1501200874-project-ares-e34-540i-6-12489281_10201285344651505_2652757086259120501_o.jpg)
After daily driving for 1.5 years it came time to address the clutch, as it was already grabbing at the end of the pedal stroke since day one.
I opt'd to pull the drivetrain, clean things up. Replace & modify a few things.
![Name: 20160308_134119.jpg
Views: 671
Size: 669.2 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152062d1501200874-project-ares-e34-540i-6-20160308_134119.jpg)
I also wanted to dial in some custom cam timing, and add a few bolt on's while it was out:
![Name: IMG_3705.jpg
Views: 620
Size: 518.0 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152063d1501200874-project-ares-e34-540i-6-img_3705.jpg)
![Name: IMG_3721.jpg
Views: 648
Size: 683.5 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152064d1501200874-project-ares-e34-540i-6-img_3721.jpg)
The OE cam timing uses a 246°/242° duration on a 109°ICL with 108°LSA. I advanced intake cams and retarded exhaust cams for a 106°ICL./106°LSA. Nothing drastic, just a little increase in dynamic compression and valve overlap.
![Name: IMG_3741.jpg
Views: 633
Size: 656.0 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152065d1501200874-project-ares-e34-540i-6-img_3741.jpg)
Spec lightweight single mass flywheel, Spec StageII kevlar clutch:
![Name: IMG_3959.jpg
Views: 664
Size: 695.8 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152066d1501200874-project-ares-e34-540i-6-img_3959.jpg)
![Name: IMG_3967.jpg
Views: 639
Size: 600.6 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152067d1501200874-project-ares-e34-540i-6-img_3967.jpg)
![Name: IMG_3955.jpg
Views: 708
Size: 786.4 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152068d1501200874-project-ares-e34-540i-6-img_3955.jpg)
![Name: IMG_4017.jpg
Views: 761
Size: 622.7 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152069d1501200874-project-ares-e34-540i-6-img_4017.jpg)
Cleaned up and painted the engine bay/body/frame. Removed ABS pump, installed manual brake bias valve. Removed leaking 540i steering gear, installed 525i steering gear converter to manual steering.
![Name: IMG_4003.jpg
Views: 711
Size: 692.8 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152070d1501200874-project-ares-e34-540i-6-img_4003.jpg)
![Name: IMG_4046.jpg
Views: 648
Size: 733.8 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152071d1501200874-project-ares-e34-540i-6-img_4046.jpg)
On the way in those aftermarket headers didn't come close to sitting in the body of the car. So the OE manifolds went back on, after a header wrap treatment.
![Name: IMG_4047.jpg
Views: 724
Size: 757.6 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152072d1501200874-project-ares-e34-540i-6-img_4047.jpg)
![Name: 2016-07-30%2011.27.55.jpg
Views: 647
Size: 243.0 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152073d1501200874-project-ares-e34-540i-6-2016-07-30%252011.27.55.jpg)
I then tackled the control arms, and then also lowered the front end a bit.
![Name: 20160731_192134.jpg
Views: 646
Size: 216.6 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152074d1501200874-project-ares-e34-540i-6-20160731_192134.jpg)
![Name: 20160801_101550.jpg
Views: 644
Size: 245.0 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152075d1501200874-project-ares-e34-540i-6-20160801_101550.jpg)
![Name: 2016-08-02%2020.45.01.jpg
Views: 668
Size: 234.6 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152076d1501200874-project-ares-e34-540i-6-2016-08-02%252020.45.01.jpg)
![Name: 2016-08-01%2015.08.49.jpg
Views: 675
Size: 202.0 KB](https://5series.net/forums/attachments/e34-e28-e12-discussion-44/152077d1501200874-project-ares-e34-540i-6-2016-08-01%252015.08.49.jpg)
It's going in for an alignment and to have new exhaust pipes made this week. I'll keep modifying it, and tweaking it. The computer tuning and speed density conversion will take a bit. I have toyed with idea of adding nitrous. But really, the only other major mod I have planned is to rid of the 2.91:1 open rear differential and rebuild it using E46 M3 210mm 3.64:1 gears and limited slip carrier.
#2
New Members
Thread Starter
Join Date: Dec 2014
Location: Prescott, Az
Posts: 5
Likes: 0
Received 0 Likes
on
0 Posts
My Ride: E34 540i/6
Model Year: 1995
Engine: M60B40
#3
New Members
Thread Starter
Join Date: Dec 2014
Location: Prescott, Az
Posts: 5
Likes: 0
Received 0 Likes
on
0 Posts
My Ride: E34 540i/6
Model Year: 1995
Engine: M60B40
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08-19-2015 09:56 AM