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  1. #1
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    A proper boosted S62 build by Discovery Automotive - 622 whp

    We don't see many S62 builds for forced induction, why is that? Well, for one, the cylinder walls are pretty thin as the motor is at max displacement. On stock internals it won't take too much. Properly building the motor is freaking expensive.

    The best S62 builds have been by Discovery Automotive. Their stuff does not come cheap. However, they do the job correctly.

    Check out this M5 build:

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    Dyno of the car at only 6,000 rpm (it will spin to 8,000):

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    Specs of the build:

    Engine Internals:

    Cryo'd block
    Coated block
    Custom Darten flanged steel sleeves were installed to eliminate the concerns with the OEM Alusil coated aluminum cylinder bores
    Custom spec'd Arias 9.5 CR pistons were fabricated
    Custom rings were spec'd for this project
    Custom spec'd Carrillo rods
    New head and main bolts
    Multi-layered head gasket
    Fully ported and flow matched cylinder heads
    New over sized Stainless valves (1mm greater diameter)
    New springs
    New Guides
    New Retainers and keepers
    Schrick Cams
    New construction of crank bearing
    Micro polished crank

    During the course of the rebuild all soft items such as water pump, thermostat, etc. were replaced.

    Engine Externals:

    Powder coated valve covers and lower plenum
    D/A Custom CF intake
    D/A Custom CF plenum cover
    Vortech D/A Shadowman Custom T1 Blower
    D/A Custom Fuel Rail
    D/A Custom Fuel Injectors , a total of 16 injectors operating in this system
    D/A Custom Velocity stacks with integrated injector bosses
    D/A Custom modified lower plenum
    D/A Custom oil separator and crankcase breather system
    D/A Custom fully programmable by-pass system
    D/A Custom billet lower pulley with Supercharger drive integrated
    Pre-loaded self adjusting Supercharger belt tensioner
    AquaMist injection, fully map able system
    Custom water/air heat exchanger
    Custom liquid charge cooler
    Nitrous Express N-tercooler
    Relocated the oil filter and the power steering reservoir from the left to right side.
    D/A Custom stainless steel oil transfer manifolds under the motor
    Extensive use of Aero Quip lines and fittings throughout the build
    High efficiency radiator
    Electric fan conversion
    Supersprint 4-1 Coated Headers
    HJS Custom Metal Cats
    Supersprint X-pipe
    Kelleners Sport exhaust

    Engine Management:

    D/A Custom Shadowman DME and system integration Software Program
    Desno Iridium Plugs
    Ignition Solutions plasma coils
    HKS O2 and knock monitor aka A/F Knock Amp with A/F monitoring integrated

    Drive train:

    UUC Motorwerks Stage III 6puck carbon Clutch
    UUC Motorwerks LWFW
    Custom Driveshaft
    Koala Motorsport prepared Diff with 3.45 gears
    Rear Sub frame brace
    Build process:

    Starting with the block:

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    Here is a picture of the surface/deck of the fully machined block with a pair of the Darten sleeves visibly pressed in place:

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    The Engine internals, 9.5:1 compression pistons, carillo rods:

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    Getting to work:

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    Here is a picture of the DCS pump now neatly mounted inside the frame rail. This particular modification is required in order to proper place the intake tube and the two mass air flow sensors:

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    Final assembly:

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    Custom water injection tanks designed to fit behind the fender on the driver's side……all they require are for the bungs to be installed for the BMW OEM level sensor, the BMW OEM filler neck assembly, a vent hose, and the feed line for the fully map able Aquamist water injection system:

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    Being prepared to fit the Supercharger and supporting pieces:

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    I'm not exactly sure which Vortech unit this is:

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    Using a Nitrous Express N-tercooler setup on the heat exhanger, nitrous or C02 is used for cooling on the exterior:

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    The comparison of the new higher boost pulley compared to the first pulley. Estimation is now at 22lbs of boost with this pully set up:

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    Carbon Fiber discharge tubes having the water injection bungs bonded in place:

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    Very nice intake:

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    What wiring should look like:

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    The Ntercooler system in use:

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    The finished product:

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    The dyno runs we have done were for tuning purposes only. We can share that at 6000rpm the engine was putting down well over 600rwhp running only a little more then half its boost. When at its full peak potential the Blower will be at 22lbs. boost:

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    This car supposedly will make over 800 whp which I don't doubt. How much does a build like this cost? Well, D/A won't share prices as I asked a few years ago. Their setups are tailored to the individual so not an off the shelf kit. It also does not have an off the shelf price, expect to pay well over 30k.

  2. #2
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    that 1 sick m5! love the e39...always thought of it as a sleeper
    Current:
    13 E92 M3 ZCP
    - WSIR 1:33:9 / BW C13 2:03:5 / ACS 1:56:7
    (Stock besides wheels/tires - Rs3)
    WSIR 1:32:8 / BW C13 1:59:2 / ACS 1:55:1
    (KW ClubSport 3 way / Rs3)
    WSIR 1:30:9 / BW C13 1:57:7
    (above plus Apr Wing)

  3. #3
    Join Date
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    Click here to enlarge Originally Posted by sammyrusso Click here to enlarge
    This quote is hidden because you are ignoring this member. Show Quote
    that 1 sick m5! love the e39...always thought of it as a sleeper
    I have always liked the E39 M5 as well... even toying with the idea of picking one up.

  4. #4
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    Do it, do it.....5.0 L - more torque...manual...
    Current:
    13 E92 M3 ZCP
    - WSIR 1:33:9 / BW C13 2:03:5 / ACS 1:56:7
    (Stock besides wheels/tires - Rs3)
    WSIR 1:32:8 / BW C13 1:59:2 / ACS 1:55:1
    (KW ClubSport 3 way / Rs3)
    WSIR 1:30:9 / BW C13 1:57:7
    (above plus Apr Wing)

  5. #5
    Join Date
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    that is one sickass ride
    Current: 964 WB, 993, Panamera Turbo

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