Thanks David, yeah I've got a homegrown four channel CAN bus translator based on a PIC32MK that I'll be using at the core of this project.
I've been extremely slack with keeping this thread up to date, so time for another update.
Since the last post, the gearbox crossmember has been finished.
And fitted to the test chassis, alongside the modified propshaft (135i gearbox flange, retubed, E39 540i from CSB backwards):
Onto the next job, creating a custom coolant hardline between the coolant reservoir and electronic thermostat (still needs some brackets):
While on a roll with bending up hardlines, an oil supply hardline was fabricated as I didn't want to have -AN fittings visible off of the oil thermostat.
For this I also machined an adapter fitting for the oil thermostat.
The coolant and air conditioning hardlines I had been working on previously were also finish welded:
Next up was making the N54 engine loom use the E39 e-box grommet:
And the shift linkages were modified:
(Not quite sure where the selector rod photos went unfortunately)
Propshaft had a fresh CSB and CV joint installed:
I'd also performed the typical maintenance on the N54 I'm going to be using, namely replacing all of the gaskets I can easily access (valve cover, sump, VANOS solenoids, etc) and injector decoupling elements.
New spark plugs and coil packs (standard N54 items for now) will also be used.
Looking nice and clean in there.
Nice and clean down under too.
The next major hurdle was fabricating exhaust downpipes; there's not a lot of room to work with unfortunately.
The vehicle will need to keep the catalytic converters for passing emmissions testing during LVVTA certification, so those were extracted from a factory downpipe set.
To complete the factory-like look, some small brackets were designed and 3d printed:
And laser-cut and machine folded:
Welded on and oxygen sensors added:
I'm extremely happy with how these downpipes turned out; they're currently off being ceramic coated (in an effort to keep under-bonnet temperatures down).
A few months have also been spent working on electrical and electronics, starting off with a jump-start terminal.
The E39s all use engine-mounted jump-start terminals, while the N54 never came with an engine-mounted jump-start terminal - all usages of the N54 have them mounted on the chassis.
For this, I designed and 3d-printed a jump-start terminal that will attach to the intake manifold:
And finally printed out of PA-CF:
Mounted and wired in the fuel pump (EPKM) module:
Designed a replacement case for the Comfort Access module, allowing it to attach to the same bracket as the factory E39 PDC module:
Created an adapter loom for between the E39 X6001 and E9x X6011 / X6021 engine connectors:
The wiring is still ongoing at this stage - chipping away at it slowly.