I am Teh Edumacator.
Join Date: May 2005
Location: ATL, London, and Barcelona
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Sorry mate, there's no way to make a 540 go faster for cheap. I should know.
Your best bet is to save your money and get a Dinan supercharger. They have come way down in price and are now roughly equivalent to VF Engineering's prices, except more reliable with better customer service.
If you are going to increase power, you also need to upgrade suspension and braking.
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1999 E39 540i/6-VF Stage 1 S/C, Dinan exhaust, Dinan strut+shock braces, Dinan ltwt flywheel + clutch, Dinan Brembo BBK, Dinan monoball, H&R Springs, Koni Yellows, M5 sways, Dinan forged 18" wheels, &c.
1995 E38 740i. Highly modded. Faster than you.
Sold 2-28-07: 1997 E36 M3/4, 8-30-05 RIP 1997 528i
Lindsay fan club member.