BMW E39 540i Shed and a half budget

BMW E39 540i Shed and a half budget

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Six Fiend

Original Poster:

6,067 posts

215 months

Saturday 14th November 2015
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It's a rainy Saturday so I thought it was about time to do a Reader's Car bit on my BMW.

I've had 2 E34s previously, a 525i SE and a 540iA. I missed the V8 immensely, it was a joy to burble about in and so comfy with big leather chairs, fully electric including the headrests!

A change of circumstances or two later my health is pretty rubbish. I have a Golf 1.4TSi DSG for everyday use, easy parking outside the hospital mostly it seems (Google on my phone tells me I work there!). A sensible daily driver on a lease which is someone else's issue if it goes wrong as I can't do as much as I'd like and a simple job can take me a day or two rather than an hour, then 2 days to recover!

In July I decided on one last hurrah of V8 silliness on a budget. Good E34s are now out of my range. Everything I looked at was rusty in the expensive places and would need too much work. The best E39s were just too far for me to travel quickly and easily from Bristol.

Scanning eBay I found, in Cornwall, a dark green, 1998, E39 540i, 108k, looks tidy, has history, advert well written. We chatted on the phone and I went down the next evening from Bristol to Bodmin. I checked what I could, noted the faults I could see and went for a test drive. It drove nicely but the alignment was out. It had a new track rod end, Aha! All in all I decided I wanted it knowing over the coming months I would do a bit at a time to get it right.

It was up for £1795, I paid £1550 with MoT until March and stood scratching my head working out how to get it home. A quick phone call and the next morning at 7am my friend and I left Bristol. Kudos to the Golf, comfy and capable doing 700 miles in 24 hours. My mate drove the BMW home utterly trouble free and only costing twice as much in fuel smile

Interior – leather comfort seats (extendable thigh support is heaven for my shoddy hips and knees), heated for the passenger my side is kaput for now. All the usual electric windows, mirrors etc Dual zone climate, auto dimming mirror, rain sensing wipers, cruise, stereo controls on steering wheel, perfect pixels on dash (it'd been done just before I got it). 2 pixels out on the OBC/Radio display. Whizzy glass electric sunroof tilt/slide with blind.

Seats in good condition no rips, tears or really nasty surprises. Due some Gliptone niceness soon – they've had a quick spritz for now.

Seatbelts are meant to be cream, fronts were grey! Changed for a very clean black set. Rears will get a scrub as they're not bad. All cupholders broken so fronts replaced with blanking plate, rears with storage tray.

Headlining black with fag smoke – damp terry cloth wipe several times and it's all good.

Carpets utterly gopping. Floor mats put through washing machine and the main carpets attacked by Henry followed by some damp cloth wiping. Next spring the seats will be out and the whole lot given a wet vac.

Inside it's a very comfy and calm place to reside. It smells clean and leathery, everything bar the one heated seat works nicely. I love the sunroof!




Exterior – It's subtle. Original ambers, no fancy wheels, no chrome, a few marks here and there. Nothing shouty about it at all. Exhaust is original and hidden behind the bumper. Some clown (ahem) has even put a 520i badge on it.

The headlights were changed as one was faded beyond polishing and the other the wrong one for that car. I wanted a matching pair with correct bulb fitments. Ebay is very hit or miss when it comes to the quality of used parts. I ended up buying 3 headlights and with the two I had already made a lovely pair from scratch. Inner lenses cleaned etc. I have a box of spare bits to sell on or keep in the “just in case” area of the shed!

The boot leaked. Rear lights popped out, cleaned up thoroughly and popped back in. Boot seal removed, cleaned up and put back. Job done. Oh and there was a minor leak at the bottom of the rear screen leaking into the battery compartment. Dab of sealant saw to that.

Oily bits - Next up was the oil leak – the MoT reports mentioned oil leaks and the bills showed replacement of the rocker gaskets. My local indy BMW garage (White Cube, Fishponds, taken over by chap who worked there under previous ownership) had a look at this as I don't have a garage to work in and it kept raining. Both gaskets falling apart, spewing oil al over the engine. A certain amount of doubt was cast over the previous work! They apologised for what they had found and asked if I'd prefer to do it myself. I paid them. Also had the headlights aligned correctly at the same time. £300

Now happy the engine wasn't about to go bang I had the alignment set up by FCM in Bristol. Lee is great and does all my cars and many others for Pistonheaders. An hour of jiggery pokery and all was good. While it was up in the air we had a poke about underneath and found it to be in remarkably good nick. That was further good news.

The tyres are not very old, a matching set of Goodyear Efficient Grip. Worth a chunk of the purchase price of the car.





Next week comes the bodywork bit. The obligatory rusty wheel arch which is being cut out, along with the panel behind, and replaced.



After that it needs a brake fluid change and an auto box service. Main dealers in Bath offer a good price on this and I fancy a day out doing my Christmas shopping (probably loafing in a cafe using the internet to be fair!) Cosmetically I will give it a proper clay and polish at some point. I may be able to get hold of a large garage to keep it in for a week or so as that's how long it'll take me. Failing that it will have to wait until spring!

Driving it – This is the good bit. It's big, lazy and relaxed, trundling about at our lovely 20mph Bristol speed limits. Prod it and it goes. Flip the shift into sport mode and bury the throttle and it really goes. It's no sports car in spite of M-sport suspension. For me it's a fast lounge with a decent sound track. This is what I need in my life. When I feel utterly crap I can just get in and burble out of town, stereo off.

Petrol - I've done a trip to Devon and back, effortlessly and frugally too. At the speed limit or a touch below due to traffic I've managed a very steady 34mpg. In town I try not to think about it, but it is about 18mpg. I don't use it in town unless I have to. It's for pleasure drives out and away.

A keeper – As I said up top, this may be my last hurrah in terms of a V8 I can play with and I really like it. I plan to do the North Coast 500 next year. I don't mind spending a bit more to get it mechanically sound and looking tidy. I'm not going for concourse, just a tidy, usable treat without breaking the bank.

What's it cost? So far, with every single pipe, cap, clip, trim piece etc included it stands me at £2200. Had I been physically able to do all the work myself this would be a chunk less - about £300. I don't feel too bad about that.

I think that's about it for now. I'll pop up more as life goes on.

Edited by Six Fiend on Saturday 14th November 19:19

Six Fiend

Original Poster:

6,067 posts

215 months

Sunday 15th November 2015
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I think with one more not too bothered owner it could easily have become poorly!

I never understand why people leave so many simple jobs which could make a car great again. Mostly it's just the filth needs removing and a little bit of DIY intelligence.

Just been out for some V8 sound track. Needed a fix!

Six Fiend

Original Poster:

6,067 posts

215 months

Thursday 19th November 2015
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Wheel arch cut out, lots of metal replaced, welded, finished and sprayed. Got it back a couple of hours ago...



And some now it's had a clean...







Feels better to drive now wink

Next job is to refit the kick strips etc to the n/s/r door sill. All of a five minute job!

Edited by Six Fiend on Friday 20th November 04:02

Six Fiend

Original Poster:

6,067 posts

215 months

Thursday 19th November 2015
quotequote all
Thanks Max, I take your points, but I like the original ambers on this one. For me it's about keeping it low key and original.

As for the badge, yes I know it's the wrong one, as in not an E39 badge (yes you spotted it's off an E60), very few will notice and it's just a bit of a giggle smile I don't take life or myself too seriously. If this was an immaculate example I really would do it properly, it's not quite so pretty close up smile


Edited by Six Fiend on Thursday 19th November 17:02

Six Fiend

Original Poster:

6,067 posts

215 months

Thursday 19th November 2015
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bmthnick1981 said:
Excellent sheding but i agree get the correct e39 520i badge on it. Nice subtle car.
£30ish for a new one from BMW, doesn't sit well with my wallet as an essential item. Maybe when the brake fluid and gearbox service have been done smile

I'll keep an eye on eBay etc just in case...

Six Fiend

Original Poster:

6,067 posts

215 months

Thursday 19th November 2015
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Was going to message you this evening now he's ready to be seen and played in. Coffee next week?

Six Fiend

Original Poster:

6,067 posts

215 months

Thursday 19th November 2015
quotequote all
Jw Vw said:
Looks in great condition for it's age.

Lovely colour combo.
Thank you smile

The colour is one of my favorites! It's a good usable car, up close you can tell it's not new but hides its 17 years well smile

Six Fiend

Original Poster:

6,067 posts

215 months

Friday 20th November 2015
quotequote all
S. Gonzales Esq. said:
Time for a Bristol E39 gathering? I might be able to persuade you that 'simplifying' the exhaust system is a good idea.
Hehe, do you remember my silver E34 540i with the Brian Blessed exhaust? smile

I just popped to Tesco at Eastville and took 49.8 miles to get back to Fishponds. I like empty roads wink

Would like to hear yours from inside as I'm tempted to go a touch louder if funds allow next year...

Edited by Six Fiend on Friday 20th November 01:59

Six Fiend

Original Poster:

6,067 posts

215 months

Friday 20th November 2015
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carinaman said:
Ballpark figure for the wheelarch repair please?
£250 smile

Six Fiend

Original Poster:

6,067 posts

215 months

Saturday 21st November 2015
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carinaman said:
Six Fiend said:
£250 smile
Thanks. Less than I thought.
That was having the arch repaired with made to measure metalwork, a fibreglass repair would have been cheap but not very long lasting.
A whole rear quarter panel is about £300 and then £800 to do properly (screen out, door off, bumper off). Nobody appears to make an arch repair panel, which I reckon they could shift plenty of!

Six Fiend

Original Poster:

6,067 posts

215 months

Saturday 21st November 2015
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Hammerhead said:
That's scrubbed up really well, Pete. Brian would be most pleased smile
He would indeed. I still prefer his looks!

Had a good look at every panel after the workshop mopped it. Every bit bar the roof seems to have been painted at some point! The tell tale signs are there but it looks tidy smile

Six Fiend

Original Poster:

6,067 posts

215 months

Saturday 28th November 2015
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Was a jolly hoot smile


Six Fiend

Original Poster:

6,067 posts

215 months

Sunday 29th November 2015
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Excellent tip Leptons smile - The outer rears may get that, the middle one perhaps not!

Mr Tea you're quite right I was talking cobblers, heated sports seats to go with the M-steering wheel and M-sport suspenders. Here's the spec sheet:

Vehicle information


Type code DE62

Type 540I (EUR)

Dev. series E39 ()

Line 5

Body type LIM

Steering RL

Door count 4

Engine M62

Cubical capacity 4.40

Power 210 (286bhp)

Transmision HECK

Gearbox AUT

Colour OXFORDGRUEN METALLIC (324)

Upholstery STANDARDLEDER/BEIGE E36 SANDBEIGE E (N6SN)

Prod. date 1998-07-20


Order options
No. Description
216 SERVOTRONIC

302 ALARM SYSTEM

339 SATIN CHROME

354 GREEN STRIPE WINDSCREEN

403 GLAS ROOF, ELECTRIC

428 WARNING TRIANGLE

431 INTERIOR RR VW MIRROR W AUT ANTI-D

441 SMOKERS PACKAGE

481 SPORT SEATS F DRIVER/FRONT PASSENGER

494 SEAT HEATING F DRIVER/FRONT PASSENGER

500 HEADLIGHT WASHER SYS/INTENSIVE CLEANING

508 PARK DISTANCE CONTROL (PDC)

534 AUTOMATIC AIR CONDITIONING

540 CRUISE CONTROL

694 PREPARATION FOR CD CHANGER

704 M SPORT SUSPENSION

710 M LEATHER STEERING WHEEL

773 WOOD TRIM

812 ENGLAND VERSION

850 ADD FUEL TANK FILLING FOR EXPORT

863 EUROPE/DEALER DIRECTORY

877 DELETION CROSS-OVER OPERATION

880 ENGLISH / ON-BOARD DOCUMENTATION


Series options
No. Description
260 SIDE AIRBAG DRIVER/FRT PASSENGER

280 LT/ALY WHEELS SPOKE STYLING

411 WINDOW LIFTS, ELECTRIC

473 ARMREST, FRONT

510 HEADLIGHT BEAM-THROW CONTR. F LOW BEAM

520 FOGLIGHTS

555 ON-BOARD COMPUTER

665 RADIO BMW BUSINESS

853 LANGUAGE VERSION ENGLISH


Six Fiend

Original Poster:

6,067 posts

215 months

Sunday 7th February 2016
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Time for an update because some stuff has happened. I've used it at the weekend a lot which is against PH rules because it has too many seats and too much roof to be a weekend car. I fart in your general direction!

To prove I should only drive it at weekends I took it out on a Monday early in the New Year and promptly bent it. The hows and whys are not being divulged except to say the irony of hitting a large lump of steel in the dark warehouse complex containing the bodyshop I was visiting did not escape me, or my friendly paint man. I can laugh at such things, thank goodness!

I was quite impressed that having felt nothing I had managed to kill a headlamp, fold the wing quite neatly and put the bumper out of shape...




That looks costly, but in the tradition of shedding I've done well. My "Just in case" box of headlamp parts (you may recall I bought a load of duffers to make a good set) meant a ten minute job building a new one. I'm quite good at this now.

The wing was almost as simple. They bolt on. Off to eBay I went and searched for one and stumbled across just the part in Oxford Green for £45 delivered. It looked okay in the picture so I nabbed it. The colour match is excellent smile and the overall condition good enough for my needs.

A few personal matters (I have Cystic Fibrosis and thus spend a lot of time out of breath and in pain) meant the car standing doing nothing for a few weeks, then I needed a dry day and a good supply of codeine to take on the task.

The flat battery made moving the old barge tricky, so jump leads and Golf to the rescue. It was another few days before the sun came out but at least I had everything ready.

Replacing the wing is easy in theory - wheel off, arch liner out, unbolt and remove.

Front wheel corroded in place, wheel bolts out, lower jack very gently until it cracks free. Spend longer cleaning up the wheel and hub than doing the rest of the job!

A normal person would have taken about two hours to get it all done. The wing alignment isn't too hard. It took me all day, lots of drugs, an inhaler and a lot of sitting looking at it, coughing, and calling myself a silly bugger!

The bumper needs work but that can wait until after the MoT later this month. It drives, that's what matters. For £45 I can't grumble. I have a new bumper insert too, £17.



After that pic I took it for a drive to give it a good run. A comfy seat and a rumbly V8, that's all I need to feel better. Sunshine so I can open the roof would be good.


Edited by Six Fiend on Sunday 7th February 18:15

Six Fiend

Original Poster:

6,067 posts

215 months

Monday 8th February 2016
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Cheers Huff, didn't manage to crawl out until 12:30pm. Will have to do another coffee before long.

Thanks Mr Tidy smile I have no need for one either but it does make life better! As a child I dreamed of having cars with big engines, just loved the sounds of the neighbours' cars.

Hammerhead, that's quite called for wink

Six Fiend

Original Poster:

6,067 posts

215 months

Thursday 3rd March 2016
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MoT passed with only an advisory for an oil leak.

This may well be remnants from the cam covers as it had plastered everything. Nothing is dripping onto the drive so I've purchased some Power Maxed tfr and engine degreaser. Once the weather is far warmer the under tray and front bumper will come off and it'll get a good clean.

Today I've changed the original candles for Osram Nightbreaker Plus Superfandango items, 12v 51w as per standard but they do seem brighter. Will pop out for a drive in the dark soon...

Dear manufacturers, the bulb change takes approximately 1 minute per side. This is how it should be. No tools, no scraped knuckles and no dealer visit.