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  1. #1
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    S62's twin supercharged E39 M5

    About time we got a thread up on this, in @s62's words:

    Here are a few pics, vids and info on my 1999 Avus Blue M5.

    Got it bone stock in August 2005:
    Click here to enlarge

    The mod bug bit me soon and here are a few pics taken after
    I added the AA CAI, full exhaust and Hamann 19" wheels:
    Click here to enlarge

    Click here to enlarge

    The sound the car made after the exhaust install was very nice Click here to enlarge
    http://www.onno.is/thordur/m5/pust/M5_driveaway.wmv
    http://www.onno.is/thordur/m5/pust/M5_rev.wmv

    Soon after it got KWv3 coilovers and Brembo BBK:
    Click here to enlarge

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    Added some angelibrights to match the angel eyes to the headlights, here you
    can see the difference:
    Click here to enlarge

    After all these mods I took the car on a trip around Europe:
    http://www.m5board.com/vbulletin/showthread.php?t=74532

    During this trip I took the car to Nurburgring where I managed
    to destroy the diff. While changing my diff the BMW shop also
    changed the propshaft and gearbox!!!! (read more about that in the trip thread)

    But that was not bad since now the car was ready for what was coming
    next....... twin superchargers!!

    Had then installed in Sweden and the setup blew the engine on
    day 2 after I got it back Click here to enlarge :furious:

    After this setback it was decided to get another block and have
    it sleeved and build a strong motor Click here to enlarge

    Click here to enlarge

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    Discrete install Click here to enlarge

    Broke the new engine in on my way to the Ring and the
    first run on full blast was actually on the Ring :wobble:
    In hindsight not smart but getting the DSC flashing at
    160km/h is interesting.

    Fun to drift too:
    Click here to enlarge

    Just donīt seem to last at all!!!
    Click here to enlarge

    Last winter I also did some "visual" mods, mostly CF
    stuff (hood, splitter, kidneys, diffuser, roof&lip spoiler
    and interior trim).

    Click here to enlarge

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    Iīm VERY happy with the car and itīs a dream to drive. The power is
    ca. 600hp/700Nm Click here to enlarge
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    Took it to Germany again this summer - here are 2 video clips, one high speed run
    and then a comparison run with a stock M5.

    http://www.onno.is/thordur/almennt/E...007/310kmh.wmv

    http://www.onno.is/thordur/almennt/E...007/tekinn.wmv

    Some pics from Nurburgring:
    Click here to enlarge

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    Mod info:

    Rebuilt motor with steel sleeves, forged pistons, 10.5:1 compression
    Twin Rotrex C30-74 blowers with individual oil system, Setrab oil coolers
    Bosch motorsport injectors and fuel pump
    Front mount intercooler
    Reprogrammed original ECU

    Racelogic traction control

    UUC "V12" Cerametallic clutch
    UUC lightweight flywheel
    UUC EVO3 shortshift kit

    Supersprint headers and race cats
    Tubi Rumore catback exhaust

    Brembo GT brakes, 355mm front, 345mm back.

    KWv3 coilovers

    19" Hamann PG2 wheels, 8.5" front, 10" rear
    Bridgestone SO3, 245/35 front, 275/30 back

    Strongstrut strutbrace

    Angel eyes upgrade with angelibright
    Facelift rear lights (LED)

    Vorsteiner GTR hood
    Hamann replica CF front splitter
    ACS replica CF roof spoiler
    ACS replica CF diffuser
    Rear lip spoiler in CF
    Kidneys in CF

    Phatbox MP3 player - 80gb
    Upgraded speakers and subwoofer from BSW

    Fire extinguisher

  2. #2
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    Some more good info:

    Click here to enlarge Originally Posted by s62
    I think the lesson here is that the stock M5 engine cannot cope with
    huge torque levels. The block flexes too much since itīs made out of
    aluminium. There is a new kit coming out that is designed by the
    same guy that did my motor(http://www.m5board.com/vbulletin/sho...d.php?t=110418
    and that will work on stock internals. This kit has lower power levels.

    The boost I have been running is about 0.5 - 0.6 bar before and after
    the block cracked.

    I have no idea how they crashed the Carrera GT and the Ferrari but
    it seemed to be a good job.

    I have taken the M5 to the dragstrip on 19" street tires and my
    best runs were:

    12.617 @ 116.57
    12.731 @ 116.27
    12.613 @ 115.67

  3. #3
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    More good stuff:

    Just got some new rear tires and decided to scrub them before
    street use.... Click here to enlarge

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  4. #4
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    MOAR:

    Been installing some new stuff. Replaced the blow off valves with
    another ones that are just a tiny bit bigger Click here to enlarge

    Click here to enlarge

    Click here to enlarge

    Finally got the new CF plenum cover and when installing it I also replaced
    the idle control valve.

    Here I have removed all the stuff on top of the motor:
    Click here to enlarge
    The idle control valve is the part with the green sticker.

    Parts all over the place:
    Click here to enlarge

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    New valve installed:
    Click here to enlarge

    Everything being reassembled again:
    Click here to enlarge

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    The new plenum cover:
    Click here to enlarge

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    Had to source new bolts since the original ones didnīt fit:
    Click here to enlarge

    Plenum cover on:
    Click here to enlarge

    All hoses on and tightened:
    Click here to enlarge

    Lo and behold.... it started up again Click here to enlarge

  5. #5
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    Removed the supercharger today:

    Click here to enlarge

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    No wonder it was making a loud noise!!!

  6. #6
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    Started cleaning out the intake today:
    Click here to enlarge

    A lot of oil and aluminium filings/bits came out of the bottom of the intercooler!

    Decided to fast-forward the drying process:
    Click here to enlarge

    Then itīs reassembling the front and install the new SC Click here to enlarge

  7. #7
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    Here is the result of crappy Icelandic roads Click here to enlarge
    Click here to enlarge

    The "nut" or whatever it is called that the coil sits on was broken off Click here to enlarge
    Click here to enlarge

    New & better ones have been machined and will be installed soon.

    I was attending a BMW meet here in Iceland when this happened - was passing a camera
    van when I hit a hole in the road. The video hopefully turns out nice,
    only have seen a small preview you can see here:
    http://turbocrew.is/videogallery/video7.php

    Also - here are some pics from the meet (taken by two of the Icelandic BMW club members),
    nice mix of cars (rather many E30's though.... ouich):
    Click here to enlarge

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  8. #8
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    I miss my PG2s. Thanks, great thread.

  9. #9
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    Yes Reputation No
    Click here to enlarge Originally Posted by BigM62 Click here to enlarge
    I miss my PG2s. Thanks, great thread.
    Yep, his car deserved some attention.

  10. #10
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    2 out of 2 members liked this post. Yes Reputation No
    Some more from m5board:

    "One boardmember has a SC beast with the AA kit. He is having some problems with the SC belt and I was asked to help. Instead of just
    emailing him directly I decided to let you all see the joys of
    owning a custom SC beast - it is not always easy when there is
    no "FI dealership" to take the car to. This is a translation
    of a post I posted on the Icelandic BMW forum in 2007.


    ================================================== ==================


    As most people know there has been a problem with the blower belt.


    Have tried many things - even "alternative medicine" with an outfit
    well versed in superchargers.......:
    Click here to enlarge


    Click here to enlarge


    Click here to enlarge


    Tried getting better tension on the belt by changing the position of the
    tensioning wheel but it didnīt work too well.


    This one belongs to a guy I know and he was the original owner of my M5 - AMG Carlsson SL55:
    Click here to enlarge


    Here is an image/diagram of the belt system:
    Click here to enlarge


    What has been scribbled onto the image is: Crank shaft pulley (A) turns clockwise
    and then the belt goes around pulley (B) then past pulley (C) and wraps around the
    supercharger pulley (D) then over tensioner pulley (E) and finally around the
    other supercharger pulley (F) and then returning to the crankshaft pulley (A).


    The problem with this arrangement is that there is just one 7rib belt turning
    both blowers. On the F-A segment there is full tension, approx. half on the D-F
    segment and the main problem has been the A-D segment because there the belt
    tends to slack/flap. The belt has most often been going off blower pulley D.


    I have smaller sc pulleys than the stock Alutech kit so that may contribute to
    the problem.


    The Racelogic traction control also intensifies this problem because the crank pulley (A)
    rapidly changes speed - sending "waves" along the belt, making it jump off the pulleys.


    Anyways, at the last club meeting at the quarter mile track the alternator belt snapped
    and the sc belt jumped one rib. Booked an appointment at a competent machine shop and
    took the car to them:
    Click here to enlarge


    These guys have alot of experience building custom stuff for 4x4's and are very good.


    Here is what we found when we removed the undertray Click here to enlarge
    Click here to enlarge


    Upon inspection some things were found. We most likely found the reason why the
    alternator belt has snapped twice. One of the fasteners for the supercharger bracket
    has been rubbing against the belt during hard pulls. We took the piece and made it
    a bit smaller so now that problem should be gone. You can see the piece at the center
    of this picture below the alternator belt:


    Click here to enlarge


    Then we made a new pulley (C) and put a sidewall on it so try to keep the belt from jumping
    off the sc pulley (D)


    Also pulled the blower pulleys of and also put a sidewall to keep the belt on:
    Click here to enlarge


    Click here to enlarge


    Click here to enlarge


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    Discovered that the water pump wheel was broken:
    Click here to enlarge


    Put another one in:
    Click here to enlarge


    Here is the revised belt system - version 1:
    Click here to enlarge


    Went for a test drive feeling very hopeful. But after some thrasing around with the
    traction control engaged the belt went. It had flipped itself on blower pulley D.
    The belt had "climbed up" the sidewall and turned.


    So back to the shop and now we unfastened the sc bracket to add a wheel/pulley:


    Click here to enlarge


    Here the new wheel is on and belt being installed:
    Click here to enlarge


    A closer look. The idea here was to make it impossible for the belt to climb up the
    sidewall by clamping it against the other wheel:
    Click here to enlarge


    Also installed a new bolt for the plenum cover - it had broken off:
    Click here to enlarge


    Then we went for a test drive. The guys from the shop were 100% sure that this would
    work "the belt cannot go anywhere". I warned them that this car might have another
    ideas....


    Anyways, 15 minutes later the belt had flipped again.


    Now we took a break from this and I thought of solutions in the meantime.


    A week later we continued and took a step back before we went forward:


    Click here to enlarge


    Now installed the original (C) pulley because it had become apparent that
    we could not use a sidewall on the wheel to guide the belt - the B-D segment is
    just too long, the belt can flap enough to climb up the sidewall.


    So now the solution was not to try to guide that belt on the B-D segment but
    try to have wheels on each side to keep it from flapping:


    Here the bracked has been unfastened and you can see the black marks that the
    flapping belt has left:
    Click here to enlarge


    Drilled a hole to put a bolt in:
    Click here to enlarge


    Not alot of space so we just used a bolt with 5 bearings:
    Click here to enlarge


    Click here to enlarge


    So basically the belt does not touch these 2 wheels unless there is alot of action
    going on. You can see I was by this time using 6 rib belts because I was out of the
    7 rib ones....


    Then went for a test drive. Now the sc pulleys were fine but instead the belt jumped
    off the crank pulley!!!


    So now we made sidewalls for the crank pulley:
    Click here to enlarge


    Click here to enlarge


    Click here to enlarge


    Click here to enlarge


    Put the sucker back in:
    Click here to enlarge


    Installed:
    Click here to enlarge


    Click here to enlarge


    Now we were very confident and went for a test drive. As we entered the nearest
    freeway I accelerated briskly and there was a loud "poof" sound and the engine
    dies - "ENGINE FAILSAFE MODE" displayed on the dash.


    Just great!


    As we stopped and opened the hood it turned out to be a minor issue, one of the
    plenum intake hoses had popped off. After we put it back on we drove on. A bit later
    I started to feel some vibration coming from the engine. Stopped immediately and
    was quick to see what the problem was..... a broke fan blade.


    The mistake we had made is not taking into account the added thickness of the sidewall
    we added to the crank pulley. When the engine started to move during load the fan
    blade just touched the sidewall and broke off.
    Click here to enlarge


    So we made a spacer that is the same thickness as the sidewall to move the fan
    outward:
    Click here to enlarge


    Then it was finally finished.


    ================================================== ====================================


    This system has eliminated all problems with the belt and has worked flawlessly since
    2007. I know that in an ideal world you should not have to add these sidewalls to the
    pulleys and everything should just be in alignment and work that way. But this works.


    A good addition would be to add an active tensioner but I have not gotten around
    to that yet and as they say.... if it aint broke....


    Hope you liked this."

  11. #11
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    Click here to enlarge Originally Posted by s62 Click here to enlarge
    Hope you liked this.
    Sure did.

    #s62

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    Lots of stuff i had not seen before... although i had been a fan of this build for a very long time...

    cool stuff Click here to enlarge
    Click here to enlarge

  13. #13
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    Awesome Awesome thread! Good work.
    Click here to enlarge



    EURO 04 M3 Current Mods:GC DAs, Eibach Sways, PF RTAB's, RE RCAs, INTRAVEE II, Black Roundels, ///MFEST Badges, Depo's, Screen protector for NAV display, VCSL Bumper + Race Lip & CF Trunk & CF Rear Diffusor, DIETZ TV in Motion, SS= V1 Headers + catless pipes + X-Pipe + SS Sport Exhaust, Z8 Starter Button, Lamin-X, OEM CSL interior, OEM CSL Steering, OEM CSL Intake, OEM CSL Roof, MSS54HP + OEM CSL Tune, BBS CH's, LIGHTWERKZ, 355mm ST40 BBK, BW Oil Cooler....

  14. #14
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    DAMN thats a lot of belts lol

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    2 out of 2 members liked this post. Yes Reputation No
    As S62 is a friend and colleague of mine i have been in this car countless of times.
    I can safely say that this is most likely the fastest daily used car (and i mean daily as in every day all day, rain or shine and even snow).As he already knows i think this car has a personality and its basically a biatch! The power delivery is simply smooth like it was build by BMW like this except waayyy more than OEM and the more you aggravate it the more pissed off it gets yet it still doesnt try to kill you!!!! In an ideal world everyone would have a daily like this!

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    1 out of 1 members liked this post. Yes Reputation No
    Here is a trip report from a massive Eurotrip in this car back in 2006:

    http://www.m5board.com/vbulletin/e39...k-warning.html

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    So awesome. So you are the guy with the twin rotrex setup, i always thought you had a twin screw setup. Great setup nonetheless Click here to enlarge

    Click here to enlarge
    Click here to enlarge

    That E30 Cabrio has M62 under the hood, right?

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  20. #20
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    Yes Reputation No
    Click here to enlarge Originally Posted by s62 Click here to enlarge
    Here is a trip report from a massive Eurotrip in this car back in 2006:

    http://www.m5board.com/vbulletin/e39...k-warning.html
    Reposting for you. Remember, all you have to do is quote your post and copy/paste it here:

    Here are a few pictures from my European vacation this spring.

    Me and my girlfriend went in the beginning of April on the ferry from Iceland to Denmark. From there we drove down through Germany and Austria to Italy and stayed for most of the time in Tuscany. We then drove back up to Frankfurt where my girlfriend flew back and I went to the Nurburgring :biggrinbounce:

    Here is the trip in words and pictures.

    The first fuel stop in the south of Iceland Click here to enlarge
    Click here to enlarge

    Not quite spring yet in the east of Iceland:
    Click here to enlarge

    ... not at all!!! :shock:
    Click here to enlarge

    We managed though to get all the way to the town of Seydisfjordur where the ferry stops:
    Click here to enlarge

    Started by changing to the summer wheels/tyres:
    Click here to enlarge

    The Hamanns now mounted and waiting to get aboard the ferry:
    Click here to enlarge

    Got all the stuff into the cabin and have strategically positioned myself so I can get the laptop plugged in.....:
    Click here to enlarge

    Our first stop was in the Faroe Islands and it was kind of chilly:
    Click here to enlarge

    Rum + coke along with some good movies on the laptop made time go by more quickly..... 8) :
    Click here to enlarge

    The cars were rather tightly packed on the cardeck:
    Click here to enlarge

    Here we are in Denmark and visited Legoland which was a nice surprise!! :
    Click here to enlarge

    Amazing detail:
    Click here to enlarge

    Here I have my new rear tyres mounted in Hamburg and have cleaned the car up a bit - ready for Autobahn:
    Click here to enlarge

    Here is the hotel we stayed at in Dinkelsbuhl in the south of Germany, second house from the left - brilliant hotel:
    Click here to enlarge

    The streets of Dinkelsbuhl:
    Click here to enlarge

    Here we are driving down to Fussen - starting to see SNOW!!!!
    Click here to enlarge

    Not getting any better....:
    Click here to enlarge

    Houston, we have a problem!!! Click here to enlargeoohhh: Click here to enlargeoohhh: These were the conditions around Fussen.
    Click here to enlarge

    Here we decided to change plans, turned around and went to the east and then down to Austria. Here we are coming down on the Austrian side, rather steep and "Emergency roads" to save you if your brakes fail:
    Click here to enlarge

    If they do you can steer the car up the slope and hope for the best:
    Click here to enlarge

    Here we are coming down the Alps on the Italian side:
    Click here to enlarge

    Here we are down on the plains - just been through snow and blizzards!!!
    Click here to enlarge

    The next day we went to Siena. Here I have parked the car in a good spot, in the shadow and noone can give me doordings Click here to enlarge
    Click here to enlarge

    The main square in Siena:
    Click here to enlarge

    Another one from the square:
    Click here to enlarge

    Inside the Duomo in Siena - marble everywhere:
    Notice the heads that are above the pillars/arches.
    (a bit tricky to photograph since one cannot use flash)
    Click here to enlarge

    Here is a closeup of the heads, these are the popes....:
    Click here to enlarge

    This church is amazing, the detail is breathtaking:
    Click here to enlarge

    Then on our way back we drove through the Chianti wine district and its small towns:
    Click here to enlarge

    Here we are in Castellini that is a small town that used to be a fort with constant fighting going on. The building above the car way back is a part of the old fort wall:
    Click here to enlarge

    My girlfriend looking out of one the holes on the fort wall:
    Click here to enlarge

    This car was in the parking lot - always liked those:
    Click here to enlarge

    And they also had this modded one:
    Click here to enlarge
    Click here to enlarge

    Here is a small video where I was having fun in one of the tunnels in Italy Click here to enlarge
    http://www.rngtoy.com/thordur/m5/eurotrip/tunnel.wmv


    More to follow.

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    Thats great man.

    I havent enjoyed reading about another persons car that much in a long time.

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    1 out of 1 members liked this post. Yes Reputation No
    very nice

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    @s62 , you are my hero! thanks for sharing so much information, i hope to be driving an S62 soon! Thanks for posting Sticky!

    Click here to enlarge

    /
    //A L E X A N D R E 1983 Photography///ALX1983.COM

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    Awesome setup for something "ancient". What kind of power does this beast put out? I wonder how hard it would be to make a twin screw setup for the e39 m5?
    Click here to enlargeClick here to enlarge

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    The car has only once been on a dyno and that was after the initial SC install.

    Then it put out 570hp and 709Nm (crank numbers).

    After that the lower compression pistons and sleeves were installed along with smaller
    SC pulleys.

    I have done some tests with accelerometers and they pointed to approx. 620hp and recently
    there was done a GPS based test that showed 616hp and 730Nm.

    So I just say 600+

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