aja540i

So I decided to install an aftermarket stereo because reasons, and I thought " I'll make this easy on myself and just get a fitting kit", that arrived today and I had a look and decided I don't want to use it, it means the flappy lid just sits up in the dash chilling, and all the space around the head unit is wasted, and I want to put a boost gauge there, so I have decided to make it amazingly more complicated... Step one, some light dismantling, with the angle grinder... Step 2, relocate the part of the frame that holds the stereo and weld it back on, it will sit further back into the dash and be angled very slightly uphill and toward the driver... Step 3, think to myself " that was a bit sh1t to weld" pick up the bracket, watch it break in half, check the casting, realize it is Magnesium alloy, start again....

Compulsory E39 headlight polish...

Removed the drivers seat, good news is the budget for this project has increased by $3.20, bad news is those are mostly potato chips..... Looks like I will be spending some time in here with the carpet cleaner!!

Legend! Apparently every e39 uses the same handbrake shoes, except the M5....

That is not actually a bumper, it is a prototype fishing net made of recycled BMW parts and cable ties, the lights are to attract fish....

More new goodies, $470 worth of gas struts for the tailgate!! Investigated the handbrake issue, the shoes have plenty of meat on them, but have big grooves all the way around and cracks across the surface so it will be getting new ones, also found a boost gauge in storage, so it will get that as well More cleaning inside, starting to reassemble the interior, still needs a new drivers seat belt, but have started the wood grain delete...

Gave it a good wash and it came up very slightly less terrible... Also some new pollen filters arrived

Not if I wanted the redline to actually mean anything!!

If you need to cut it give me a yell, I have a plasma cutter that will make holes in it!

did the rounds of Pick a part this afternoon, got a replacement steering wheel for $29, same 4 spoke wheel but MUCH nicer condition, a few bits of trim, and a donor instrument cluster to change the original from MPH to KPH, I'm leaving the MPG on the economy gage to trigger those who prefer their miles In metric!!

Just grind some notches in the sway bar, will be mint as bro!

Diesel leak sorted ( hopefully) also removed all the crud from the fuel cooler and its pipe, vacuum cleaner is earning its pay on this one!!

Just cleaned 22 years worth of shite out of the egr valve, seems to still be working, I will hook it up to some vacuum tomorrow to make sure the diaphragm is intact, chuck a new vacuum hose on it and it can go back in. Also found the diesel leak, inlet hose to the high pressure pump, so will sort that before the manifold goes back on, slow but good progress!

So swirl flaps are not an issue, doesn't have any, never did! thick, black, gunk on the other hand, it has plenty of!!

Its seems they are either quite slack or far too over the top, it would be nice to have more consistency. I have been using Continental BMW and they do a great job on WOFs.

It appears that it has had a set of shocks, but about 10 years ago! No evidence of any other suspension work....handles like 22 year old suspension. I will start on those bits once it is road legal.

Old vs new! At some stage I will replace it with the cyclone type, but this will do for now.

no, the 540 was Biarritz Blau, this is Orient blau, quite a bit darker. Yes the Mrs is distracted by her Lamborghini for now, but I suspect this will come up again in the future!! Have you finished the Defender yet?

Definitely the old type, possibly the original part from1998, black, crunchy, foul smelling mess! 2ill upgrade to the new design part. Still has the egr and I can't see but I'm guessing the swirl flaps as well.

Started on the most pressing issue, there is an issue with the selector / key link cable and it won't release the key when in park, so the key can't be turned off and removed, removed centre console and steering column covers to sort it. Bonus cassette in the stereo!! Plays right through, both sides! Interior is absolutely filthy but not in bad shape otherwise. Edit: fixed, interlink cable adjusted, keys turns off and can be removed!

E60/61 M5 clutch and flywheel done by BMW was $5k.

I am aware they can die, but it is doing everything it should at the moment so I will give it a service and hope for the best!

awesome thanks, when its all legal you can take it for a spin!

Thats what I am assuming, it has had a lot of oil changes but not much else in terms of maintenance. It will also be interesting to count the swirl flaps.....

Not sure that fun is the best choice of words but something will begin! Just reading through the service history, came to nz around 2003, has had 4 sets of front brake rotors and 3 skims!! Will start with basics, wof issues, polish headlights, slow leak in tyre, etc, then check on swirl flaps, egr, and turbo. It smokes like hell when its cold, nice blue oil smoke, so that will need sorting....