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    • Evolve Automotive Stage 2 Intercooled Roxtrex C38-91 Supercharged E39 M5 S62 V8 build results - +144 horsepower

      We finished up and delivered this carbon black BMW E39 M5 back to the owner last Friday. We thought it would make interesting reading and viewing to take pictures at various stages of the build to get a better understanding of the components that make up our Stage 2 (intercooled) kit for this car. I say Stage 2 but we decided not to go ahead with production Stage 1 (non intercooled) kits. The reason for this is because the inlet air temperatures would get very high and we were not happy with the consistency or power delivery.


      For us consistency was key and that meant providing an intercooled version preferably using an air to air intercooler. The challenge with an air to air intercooler was where to put it without cutting/trimming parts of the car if choosing a tradional front mount position. Our solution? What we refer to as a side mount intercooler placed in front of the front wheel/behind the fog light area. To allow maximum effeciency we use customised fog light surrounds with mesh and modifiy the wheel arch liner to allow air to flow through this area. The intercooler also has cowling to force air into it. The result is an intercooler that helps the car make consistent power without having to trim parts off the front of the car whilst looking very stealthy.

      Initial thoughts from the customer are that the has an amazing powerband and that it consistently makes power after repeated runs. More feedback will be provided once the customer has driven more extensively.


      Dyno results stock vs Evolve Stage 2 Supercharger at the flywheel. Maximum gains 144 BHP and 110 lb.ft torque.


      Dyno results stock vs Evolve Stage 2 Supercharger at the wheels. Maximum gains 102 WHP and 80 lb.ft torque at the wheels.


      Flywheel Power vs Boost


      Flywheel power vs AFR



      Evolve Supercharger bracket with pullies installed.


      Various parts laid out ready for installation.


      Rotrex C38-91 Supercharger and Carbon Fibre Intake.


      Oil Resevoir for the Rotrex C38-91.


      Setrab Oil Cooler for the Rotrex Supercharger.


      Coolant hose replacement silicon to connect to the supercharger bracket.


      Supercharger bracket in place.


      Supercharger bracket reverse view.


      Rotrex C38-91 Supercharger bolted on to the the bracket and coolant hose in place.


      Supercharger rear view.


      Supercharger and bracket front view.



      Front light removed for intercooler installation and oil lines for supercharger intsalled.


      Intercooler and cowling installed.


      Intercooler installed side detail.


      Intercooler installed rear detail.


      Carbon Fibre intake.


      Pulley detail.


      Boost tubing from supercharger to intercooler.


      Boost tube and intake tube installed.


      IAT sensor bung on cold side of intercooler.


      Belt installed.


      Install complete.


      On the dyno ready to test.






      This article was originally published in forum thread: Evolve Stage 2 Intercooled Supercharger E39 M5 build started by Imran@Evolve View original post
      Comments 18 Comments
      1. ChrisN54's Avatar
        ChrisN54 -
        Wow! Beautiful install. Must be a real blast to drive.
      1. Sticky's Avatar
        Sticky -
        Promoted to front page with some formatting changes.
      1. G0TB00ST?'s Avatar
        G0TB00ST? -
        Another great product from evolve!
      1. Kidrobot's Avatar
        Kidrobot -
        Now that this is done...please finish up the S54 kit!
      1. onisyndicate's Avatar
        onisyndicate -
        wow that is sexy. I love the e39 m5. That will probably be my BMW back into the game. Unless I can score a 135i for a decent price.

        with that power band and capabilities i bet it can give the new f10 a good run for it's money!

        1/4 mile calculator puts it out as 12.01. Which would be awesome! Built motor with vac heads and SS headers and exhaust easy tens!
      1. Group.america's Avatar
        Group.america -
        I really hate EVOLVE

        Click here to enlarge

        ... cause I avoided S62 M5 for so long but this car is always a fave of mine... great job building this out

        Can you advise us of costing with install approximately please ?
      1. LostMarine's Avatar
        LostMarine -
        lol. what i find funny about Evolves stuff, is that it takes experienced people to see its Supercharged. I cant count how many times people look right at the blower and plenum and then ask me if i have anything done to it. Once i say "yea, supercharged," they look back and go "oh, is that what that is, was wondering what it was but just figured it was a large alternator"

        then i let them drive it and they need new underpants Click here to enlarge
      1. Group.america's Avatar
        Group.america -
        Click here to enlarge Originally Posted by LostMarine Click here to enlarge
        lol. what i find funny about Evolves stuff, is that it takes experienced people to see its Supercharged. I cant count how many times people look right at the blower and plenum and then ask me if i have anything done to it. Once i say "yea, supercharged," they look back and go "oh, is that what that is, was wondering what it was but just figured it was a large alternator"

        then i let them drive it and they need new underpants Click here to enlarge

        You are a funny bloke mate

        I am glad you really aren't lost... was going to ask if you were ex Vietnam etc when I saw your moniker... a lot of my SGTs and WOs were ex NAM... good guys the lot of them
      1. benzy89's Avatar
        benzy89 -
        Awesome stuff evolve -- Incredible that the S62 stock manifold cover can withstand the boost & the sueprcharger def wakes the E39 M5 up.

        Was this also paired with your S62 headers?? Or a completely stock car + the supercharger kit?
      1. Sticky's Avatar
        Sticky -
        Good question curious on US pricing as well?
      1. LostMarine's Avatar
        LostMarine -
        Click here to enlarge Originally Posted by Group.america Click here to enlarge
        You are a funny bloke mate

        I am glad you really aren't lost... was going to ask if you were ex Vietnam etc when I saw your moniker... a lot of my SGTs and WOs were ex NAM... good guys the lot of them
        lol, i have a unique persona, some find it funny,others arrogant. no vietnam for me, im "new school"
      1. Group.america's Avatar
        Group.america -
        I got out of the military "by accident" (read luck) the day Suddam Hussein invaded Kuwait... 2 Aug 1990... was getting my commission resigned just as he crossed the border !
      1. deemo319's Avatar
        deemo319 -
        C'mon man, that is straight dope there.
      1. Imran@Evolve's Avatar
        Imran@Evolve -
        Click here to enlarge Originally Posted by onisyndicate Click here to enlarge
        wow that is sexy. I love the e39 m5. That will probably be my BMW back into the game. Unless I can score a 135i for a decent price.

        with that power band and capabilities i bet it can give the new f10 a good run for it's money!

        1/4 mile calculator puts it out as 12.01. Which would be awesome! Built motor with vac heads and SS headers and exhaust easy tens!
        Here is one we made earlier Click here to enlarge

        http://www.evolveautomotive.com/arti...-supercharger/

        Evolve built motor, Evolve heads, Evolve Headers, Cams etc.

        I have to get the dyno graph for this one.
      1. Imran@Evolve's Avatar
        Imran@Evolve -
        Click here to enlarge Originally Posted by Group.america Click here to enlarge
        I really hate EVOLVE

        Click here to enlarge

        ... cause I avoided S62 M5 for so long but this car is always a fave of mine... great job building this out

        Can you advise us of costing with install approximately please ?
        In the UK the RRP is 7500/$12000 plus taxes. We install for free here.
      1. Imran@Evolve's Avatar
        Imran@Evolve -
        Click here to enlarge Originally Posted by benzy89 Click here to enlarge
        Awesome stuff evolve -- Incredible that the S62 stock manifold cover can withstand the boost & the sueprcharger def wakes the E39 M5 up.

        Was this also paired with your S62 headers?? Or a completely stock car + the supercharger kit?
        This car had stock headers/cats.

        We have done a few cars with Evolve headers and Cats. I will get some dyno's.

        Boost is kept at this level (100mm pulle for the stock plenum to be ultra safe as going 6psi + has cracked a few plenums. I know this happens on other kits too but no one seems to talk about it. You can use a pre-preg carbon plenum top which seems to be holding more boost without any issues.
      1. onisyndicate's Avatar
        onisyndicate -
        Click here to enlarge Originally Posted by Imran@Evolve Click here to enlarge
        Here is one we made earlier Click here to enlarge

        http://www.evolveautomotive.com/arti...-supercharger/

        Evolve built motor, Evolve heads, Evolve Headers, Cams etc.

        I have to get the dyno graph for this one.

        It said 645BHP with the whole shebang! puts it roughly 11.29 on the calculator! Keeping up with a new Viper GTS yes PLEASE!
      1. undercover's Avatar
        undercover -
        would love a us customer to do the sale/install here in nj as a rep for evolve products they make nothing but the best, so glad to see the e39 market taped into!!!
        undercoverperformanceinc@gmail.com