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1988 E28M5 S38B40TL "Lucifer's Hammer"
"By the pricking in my thumbs, something wicked this way comes." W. Shakespeare: Macbeth, Act IV, Scene 1.
"Like a freight train on crack with a steroid enema."
General
Built in September, 1987, this car is #804 of 1256 US spec cars built. BMW built a total of 2241 E28M5s (568 EUR, 187 UK, 1256 USA, 134 CAN and 96 SA) bewteen October, 1984 and June 1988.
The car was purchased in September 1989 with 3103 miles on it, having been used as a demo by the Molesto, CA dealer. The price was near theft. The E34s were being introduced. In addition, the dealer was under considerable financial duress. Shortly thereafter it was handed over to Dinan Engineering in Mountain View, CA for their Stage IV suspension conversion and installation of a Dinan ECU chip. The VDO oil temp and pressure gauges were transplanted from my E23 7-series, as were the BBS RS 3-piece wheels. Used as a daily driver for almost 5 years, the car accumulated nearly 120,000 miles in the Central Valley before I returned home to Colorado in 1994. Since then, it has seen only occasional long summer trips.
The decision to refresh the engine arose from an initial desire to bring the car back to its (more or less) original crispness, normal wear and tear having taken its toll. The objectives in the rebuild were to develop maximum power outputs from the S38B35 block consistent with meeting Colorado's Enhanced Emissions standards, day-to-day-driveability essentially equivalent to a stock M5, with reliability and longevity equal to or exceeding a factory motor.
Chassis
weight and distribution: 3360 lbs wet, 1/2 tank of fuel: 1820# f (54%), 1540# r (46%)
Dinan front strut bar. 6061T6 aluminum/carbon fiber construction.
Bavarian Auto (KMac?)eccentric camber adjustment plates on front strut towers.
front strut towers reinforced--spring perches to sway bar link mounts.
Korman/Patterson rear strut bar. 4130 3/4" x 3/4" square-section aircraft tubing.
new rear subframe bushingsa (stock, as urethane trtansmitted too much vibration.
new rear Pitman arms and diff mount.
Aeromotive A-1000 main fuel pumps (2), each with 600# (360liters)/hr capacity @ 45 psi.
fuel lines resized to 5/8" to accommodate fuel flow requirements.
Aeromotive variable rate fuel flow regulator, billet pump volume controlller (1 for each pump) and back check valving.
Suspension
Dinan Stage IV suspension
~SLS load leveler removed
~adjustable rear trailing arms
~Bilstein "Sport" shocks and Mac struts
~front & rear springs manufactured for Dinan specifically for the E28M5 suspension packages
~25mm front sway bar; 19 mm rear sway bar. Both adjustable for handling requirements.
~sway bar mounts gusseted and frame location points reinforced.
~new urethane sway bar bushings, f & r.
Lemforder forged aluminum lower control arms (540I Sport); Paul Gray urethane bushings.
Lemforder upper control arms, Paul Gray urethane bushings.
Bavarian Specialties (Mike Yaskin) 22 mm strut-to-steering spacer blocks.
Brakes/Wheels
E34 Euro M5 "Nurburgring" calipers . (345 x 32 mm; 328 x 20 mm).
stock composition pads.
brake components powdercoated for corrosion resistance.
E32 25 mm master cylinder.
Bavarian Autosport stainless steel braided brake lines.
2-piece forged magnesium BBS "Style 5" wheels 8 x 17 ET20 f, 9 x 17 ET 25r. Note: rears were reworked from stock 22 mm offset.
Pneumant 950 PN950 'Tritec" 235/45ZR-17f, 255/40ZR-17 tires.
Thanks and a tip of the hat to Duke "The Scrounger" for finding the wheels Alright
Motor
Engine configuration: S38B40TL 4 valves/cyl, 4 liters (3986 cc) turbocharged inline 6-cylinder.
Motor built by Paul Burke Imagineering, Knob Noster, MO
Tuning and engine management systems by MileHigh Performance, Englewood, CO
Driveline and suspension by Bimmerhaus, Broomfield, CO
Outputs:
RWHP = 707+ hp @ 5700 rpm. RWTQ = 725+ ft-lb @ 4900 rpm.
Boost level = 14.95 psi
(These are SAE compensated values taken on an eddy current chassis dyno)
engine blueprinted for tolerances, static and dynamic balance. Total combined weight tolerance on reciprocating parts: +/- .2 gram.
align-bored, all deck and mating surfaces trued, parallel/perpendicular as required.
bored/stroked: 94.36 x 95.00 mm (3986 cc).
SCAT billet crank. 4340 steel, nitrided, stress-relieved, knife-edge counterweights. Balanced w/o drilling.
Fahey tool steel crank hub.
Carillo H-section billet rods, balanced, paired and stress-relieved. Weight 575.0 grams. Carr rod bolts.
JE 8.8:1 forged pistons Rig lands and piston crown configured for FI application. Weight 389.0 grams.
Piston skirts antifriction coated by PolyDyn, Houston, TX. JE Series 82 tool steel wrist pins. Weight 117 grams.
Total Seal ductile iron/plasma moly coat rings.
Total reciprocating mass per cylinder = 1179.6 grams, =/- .1 gram.
New bearings, seals and gaskets throughout.
Interior of block deburred for oil return; Glyptal coated.
New cam chain, sprockets & guides; E36 M3 configuration chain tensioner.
Blueprinted oil pump, raised oil baffle, new oil level sensor.
Oil spray piston cooling system per BMW M106 motor.
New oil pump, sprockets & chain.
Schrick 272 intake cam, 11 mm lift. Stock 248 exhaust.
Valves unshrouded, port and valve treatment for optimized gas flow; all guides replaced.
Exhaust track (combustion chamber, piston crowns, valves, exhaust ports) ceramic coated for heat management.
E34 38.5 mm intake, 32.5 mm exhaust valves.
E34 3.8 L intake horns.
Intake throttle bodies opened to 50 mm, polished, flow-bal;anced, matched to intake ports.
Exhaust ports opened + 2.5 mm, polished, flow-balanced, matched to exhaust manifolds/gaskets.
ARP head studs, main cap bolts/
Cometic .080" MLS head gasket.
Electromotive TEC-3r ECU. Proprietary software configuration written for this application.
Staged injectors arrangement designed and built by MileHigh Performance, Englewqood CO
2 sets of injectors, separate rails. Primaries 45#, secondaries 74# Flow and duty cycles keyed to load/boost demands.
PLX Devices M-250 wideband O2 sensor.
Calvin Elston Exhausts (Charlotte NC) equal-length tuned header system, unique to this car. Headers and entire exhaust system fabricated from .060" wall 321 stainless.
Turbo downpipe 3" into cats 2 x 5.9 L capacity RandomFlow cats, 2 x 2 1/2" exhaust-'cat back into 2 Bassani mufflers.
Complete exhaust system zirconium porcelain coated by Premier Coatings, Denver.
Urethane alternator mount bushings.
Rebuilt alternator w/ new brushes and voltage regulator integral to alternator.
Rebuilt starter; new bendix & solenoid.
6-coil Euro 3.8 M5 ignition system: coil-on-plug.
New water pump and 68 deg C thermostat.
All hoses and rubber components in engine compartment replaced at time of rebuild.
Turbo
Turbonetics T66/T4 turbocharger 66 trim (A/R .55) compressor; A/R .81 P trim turbine. Ceramic bearings,water cooled.
"Big shaft" impeller unit. Rated flow: 72#/min @ Pr =2.36. Turbine is zirconium porcelain ceramic coated for heat management by Premier Coatings, Denver.
TiAl 46 mm wastegate; 1.2 bar springs.
Turbo SX H-34 diverter valve.
Intercooler by Bell Engineering (Corky Bell). Custom unit tio fit Euro valance. Flow tested @ 1156 cfm. Bar-and-plate design. 25" w x 6" H x 4" D. < 1.2 psi pressure drop.
Estimated efficiency @ 60 mph = 78% +. Greater at higher speeds.
Driveline
VAC Motorsports 11# steel/aluminum flywheel.
Quartermaster 8.25" "Extreme V" 6-puck metallic clutch. HD pressure plate and TO bearing.
New clutch slave and master cylinder, hydraulic lines. Clutch slave upsized internally to 25.4 mm diameter.
E34M5 Getrag 280.51 upgraded trans.
UUC Shortshifter linkage.
reinforced (heavy wall) custom driveshaft from Dobbin Bros, NC.
New guibo, driveshaft center bearing/mount, Spicer U-joints.
Quaife torque-biasing differential (3.64) built by Brett Anderson (Koala Motor Sports).
Bodywork, gauges, etc.
Leather dash panel.
Miller & Norburn/VDO oil temp&pressure gauges.
das-mounted 2-stage booist control; Autometer boost gauge, EGT, A/F metering. Gauge panel built by Shawn Doughtie, Alpharetta, GA.
Brass/stainless windshield washer valving (Shawn Doughtie).
Hella Euro headlights (7"-5 3/4") H4-H1 90/100 W.
Hella H3/100 W fogs.
Euro bumpers and air dam f & r; powdercoated matte black to match "shadowline" trim.
Lower valance reshaped to accommodate Bell Engineering intercooler.
Rollup rear sunshade
Rear seat headrests.
New heater control valve internals.
"Evo 3" ///M-style 3-color powdercoat on valve cover and plenum.
driver's door coin tray.
Wide-angle exterior mirrors.
Under-spare 9-liter jerrycan.
2.4 kg. powder fire extinguisher.
Euro first aid kit in trunk receptacle.
B-Quiet "L-Comp" composite sound deadening panels behind rear seat area.
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