To build the front end to support the weight of the M5 v8, i went with the nissan 240sx hubs, and knuckles. After looking at the front susp on the nissan i decided to use the lower control arms and thurst arms as well. I made my own subframe and link mounts on the 2002.
Since I wanted to run a big brake kit but didnt want to run 17" wheels I made my own brake kit from wilwood.
Started with the firewall mock up and finished it, not as happy with the firewall as i am with the trunk floors. The trunk was only 3 panels, and the firewall was many. This is my first time doing metal work so Im learning a lot as i go.
For the steering On the vehicle, im running a BMW 320i manual rack. I had to also run some pretty crazy link setup to get around the motor in the engine bay.
Also I found out that the stock manifolds on the S62 wouldnt fit between the frame rails on the 2002, so I ended up getting exhaust manifolds from the M62 x5 engine. These manifolds hug the engine block making the motor a smaller package.
Ran into another issue, I couldnt use the factory Altenator cause it was way too big.
So I got an altenator from a Geo Tracker, and made a mounting bracket, and belt tensioner.
Here my mocked up big brake kit, and finished product. Nice part about having a friend with a laser cutter, was getting the bracket to fit nice and tight on the rotor giving enought room to clear 16" wheels, possibly 15" wheels if i found the correct offset.
Here I started to do some plumbing, and ran some brake lines. Also some chassis bracing was done to help support the extra power.
Here are some photos of the stock 2002 harness being stripped down and then removing all the electrical wiring for the factory engine. I then wired the s62 harness to work with the factory harness. I then layed it out in the vehicle and wrapped it with cloth fabric electrical tape so it would have a factory look to it.
For the turbo front bumper, i made a scoop to ram more air into the radiator to help with cooling.
For exhaust, i kept the exhaust outlet in the factory location, running 2.5" into 3"