[mashimarho]

Looking forward to it

[FlaPatsFan]

Originally Posted by bkwld

RWD is definitely way to go but if you get the car on Craigslist for good price, it’s a rare car fully loaded with blk/blk. Getting a good price however will be offset by the maintenace and fixes you will want to do since it’s 95k.

Love this thread! I picked up a 2011 328i Wagon little over a year ago. 72k for $10,500. Blk on Blk, No Xdrive, no power seats. Huge sun roof tho! Unfortunately it’s an automatic. I have done a lot of upgrades and mods to get it to a M+ level. Not to tetsuo111 level but trying. Still have things to do. Love the car and it’s look. Hopefully she will be ready for a few track days in the next few months. My question for tetsuo111 is about those seats!!! I’ve been looking into a seat swap/upgrade and can’t find much about a aftermarket racing seat install. I know OE sport seats are a easier route, but you can’t beat the look of Recaro or something similar. How much modification and extra work was it to mount them? Extra brackets/hardware? Seat belts/Air bag sensors?

[redEYEjedi]

I love E91's sooo much!

[tetsuo111]

The New Year coincides with five months since taking delivery of this car. It seems like an appropriate time to consider progress (or lack thereof) and direction for the upcoming season.

I took delivery of this Black Pearl last August. This car is the Unicorn: E91 6MT RWD ZSP with only 35k miles. I considered keeping her 100% stock. On the other hand, where's the entertainment in that? I enjoyed the last car tremendously, but am aware that some of my passengers were less thrilled. So I decided to limit mods to mostly cosmetic, at least until we had a second vehicle for family duty. Given the handling and driving-centric spirit of my last build, this one was rather mild. Too mild.

On the last car, the order of precedence was: 1) brakes 2) suspension 3) power, and 4) aesthetics. That build order worked well and I wanted to do it again. Sadly, on this car, the build lacked organization and focus, mostly because I prioritized reusing performance parts salvaged from the old car, and I wanted to keep the car "family friendly".

We took delivery of our family daily-duty vehicle recently (new Jeep Grand Cherokee). I already have an AFE Magnum GT CAI and conical air filter for the GC, and suspension upgrades in the queue, but that's another story for a different forum... So the family's happy now, and I (finally) have no reservations about moving forward on this E91.

So what's in the pipeline? My plan is an E91 -> M3 conversion, but with a twist. With inspiration from 63NP, NYBulldog, ilikebmxbikes ), and others, this wagon is getting the M3 treatment, from the inside -> out. There are no plans to install an M3 body kit, rather the focus is on the mechanical and electrical systems that differentiate an M3 from non-Ms. The conversion will probably be limited to chassis, brakes, suspension, and steering, but the conversion will be extensive within this scope. Since I'm beginning with the foundation (chassis upgraded to M3 specs), I retain the option to go all-in with a S65 at some point in the future.

2018 Updated Plan:

Phase 1: Transfer parts salvaged from the old car. Phase 1 is finished

Interior Conversion to M3+
- Recaro Profi
- M3+ interior (steering wheel, instrument cluster, interior trim, ZHP shift knob, GTS Alcantara armrest, AutoSolution SSK, M3 shifter insert)

Chassis
- M3 strut tower brace
- M3 rear chassis brace
- M3 engine cowl and microfilters
- Euro 330i rear bumper bar (10.5 lbs)

Intake
- Cyba scoops
- M Performance N52 intake
- OEM Euro N52 airbox
- Hendrick's 3" carbon fiber CAI
- AFE Pro Dry air filter
- Rev Motorsports silicon TB hose
- OEM 330i 3IM DISA intake manifold

Exterior
- M Performance black grills
- Lux A.E.

Exhaust
- Dundon Motorsports 20 gauge 321 stainless exhaust with Coast Fabrication muffler, Vibrant resonator, Inconel tips, SuperSprint mid-pipes

Phase 2: M-Performance Aerodynamics kit

I love this body kit, installed it on the old car, and was always happy to never see another like it on the road. The panels look like they were sculpted in the wind tunnel because... they are. There are obvious similarities with the body kit used by BMW teams for the WTCC and BTCC series.

When I ordered the kit last November, I learned that it's been discontinued, there are none available for sale in N America, and there are only four remaining on the Continent. Those were the last ones available to buy. I moved mountains to get them. Now I have them, they're painted and I just need time to install.

Phase 3: Chassis

The chassis is the foundation of the car. It needs to be stiff and strong. Performance parts contribute little if the chassis flexes like jello. This is why the M3 has so many chassis stiffeners and reinforcements not found on our non-Ms. I had already installed several M3 chassis braces with the glaring exception of the large front subframe reinforcement and stiffening plate. I have a stiffening plate to play with, and will figure out a way to install.

Phase 4: SuperSprint headers

These are already ceramic coated and just waiting to be installed. I will install a larger muffler on the cat-back system to mitigate noise, first.

Phase 5: The Great Unknown - Suspension, Brakes, and Steering

So if you bothered reading this far, you might wonder why the brakes and suspension are still untouched. Good question! On the last car, everything was upgraded: ST BBK, ss brake lines, TC Kline suspension, camber plates, M3 control arms, PG LSD, low-compliance drivetrain mounts, bushings, etc. The only remaining part of the old suspension was the subframe itself.

For this car it makes sense (to me) to simply install the entire M3 rear subframe and suspension, rather than do the job bit by bit. This plan appeals because I can use an M3 LSD rather than a custom LSD installed in a non-M pumpkin. In the front I'll retain the stock subframe to cradle the I6, and convert everything else: brakes, coilovers, and hubs.

The M3 hubs differ from the non-M. They're stronger, provide better damper support, and have different attachment points for the control arm geometry, for improved handling.

Phase 5: Power

The sole power upgrade in the queue is MILVs, available from CobraMarty. I have my MILVs, and will install after completing the other projects.

The Holy Grail is an S65 swap. This plan retains the option to do a swap in the future, the right way, with a proper chassis, brakes, suspension, and steering setup. If I move forward, it will only be AFTER installing the full control system suite and M3 wiring harness.

It's good having options...

[mattpete13]

loving this thread!

[kickserve]

I've been curious about what you were going to do suspension-wise (i.e. was the sport suspension going to be good enough).

Looking forward to the progress (and hoping that you stumble on a deal on a S65)!

[tetsuo111]

The interior is mostly finished after the addition of a M3 6MT kombi. I was accessing hidden menus to monitor coolant temps. The new cluster includes a temperature gauge and aesthetic details. Several miscellaneous bits and pieces are needed to convert the interior.

Turner 60A poly motor mounts were also installed recently. The last car had 034 Motorsports 50A rubber mounts. The 034 mounts were perfect for a dual use car. They're clearly less compliant compared with stock, but have zero NVH penalty. All upside with none of the hassle. In contrast, the 60A poly mounts are less compliant than both the 034 and OEM mounts. But NVH is a challenge when the motor spins less than 750 RPM. Furthermore, the nature of the NVH is different between rubber and poly. Rubber has a more forgiving nature, while poly seems to transmit more undesirable frequencies to the cabin. Even above 1k, the vibrations go away with the 60A polys, but there still seems to be a "hardness" to the NVH character.

More chassis strength and stiffness are ALWAYS welcome. The M3 has many chassis reinforcements, and most of them are invisible unless one knows where to look. The largest brace reinforces the front subframe with a large and strong aluminum panel. Non-M cars don't have this panel and use an "A-frame" truss instead. I was able to install the M3 aluminum reinforcement panel by adding 4 OEM blind rivets to the subframe. There are already holes in the frame for a perfect fit. In addition to this panel, I'm having an aluminum reinforcement bar fab'd to connect the subframe to the unibody.

[tetsuo111]

.

[E91WAG3N]

Great updates! Does the M3 under panel replace or go underneath the plastic one we have?

[tetsuo111]

Originally Posted by ubersteuer

Great updates! Does the M3 under panel replace or go underneath the plastic one we have?

Thanks. The M3 stiffening panel actually replaces the non-M plastic underbody shield.

If nothing else, this mod neatly side steps the need to remove 427,000 self-tapping screws to remove the large plastic shield. The plate is attached with six M10 bolts.

[tetsuo111]

Originally Posted by kickserve

I've been curious about what you were going to do suspension-wise (i.e. was the sport suspension going to be good enough).

Looking forward to the progress (and hoping that you stumble on a deal on a S65)!

Hi, you raise an important point. IME suspension upgrades lend themselves to enjoyment on track, while HP/TQ upgrades are more enjoyable on the road. The ZSP suspension is fine. It isn't as capable as the TCK / Koni sport I had, but it doesn't make my head explode like the OEM xDrive setup, either.

I'll get around to suspension work, but I'm simply not motivated enough to move forward. Yet....

[E91WAG3N]

Originally Posted by tetsuo111

Thanks. The M3 stiffening panel actually replaces the non-M plastic underbody shield.

If nothing else, this mod neatly side steps the need to remove 427,000 self-tapping screws to remove the large plastic shield. The plate is attached with six M10 bolts.

That's what I was hoping for! Will have to add this one to the mod queue. Besides stiffening up the front end a tad, it should have the benefit of actually protecting the oil pan somewhat in comparison to the plastic.

[Blueeyesredpanda]

#52 Pic 5, is that the Hendrick's 3" carbon fiber CAI? So it is connected from the brake air duct to the intake?

[tetsuo111]

Originally Posted by Blueeyesredpanda

#52 Pic 5, is that the Hendrick's 3" carbon fiber CAI? So it is connected from the brake air duct to the intake?

Close, but not exactly.

The M Perf Aero bumper has left and right faux air ducts. They feed the 335i aux oil cooler, but only if one buys the cooling package for the 335i.

In this case, I opened the top of the left / driver's side air duct, then routed 3" carbon fiber tubing with 45 degree bends between the bumper air duct and the airbox. The CF tubing is sourced from Hendrick Motorsports.

The brake cooling air duct can be seen in the same picture, next to the snorkel CAI. It's 100% unmolested.

[tetsuo111]

Some bits and pieces arrived last week:

Pic 1 - M3 front control arms with Syncro Designworks Mono-ball bearings, M Performance Aerodynamics CF splitter, GTS-style center console delete V2, Depo smoked side marker LEDs

Pic 2 - Syncro Design mono-ball bearings pressed into M3 arms. A standard 750ml bottle of whiskey included for scale

Pic 3 - Depo side marker LEDs installed

Pic 4 - M Performance Aero CF splitters installed

Pics 5 and 6 - GTS center console delete V2 fitting

[E91WAG3N]

Great updates!

[kickserve]

I'd argue there is nothing standard about Westland whiskey!

Awesome updates.

[mattpete13]

Love this thread - thank you for the inspiration!

[tetsuo111]

Westland seems to be getting traction, winning awards in Japan. Interestingly, the distillery is about 5 minutes from home. Very cool space with tours and samples.

I used to be a single malt guy, but prefer Westland now.

http://www.westlanddistillery.com/

Originally Posted by kickserve

I'd argue there is nothing standard about Westland whiskey!

Awesome updates.

[kickserve]

Originally Posted by tetsuo111

Westland seems to be getting traction, winning awards in Japan. Interestingly, the distillery is about 5 minutes from home. Very cool space with tours and samples.

I used to be a single malt guy, but prefer Westland now.

http://www.westlanddistillery.com/

Originally Posted by tetsuo111

Westland seems to be getting traction, winning awards in Japan. Interestingly, the distillery is about 5 minutes from home. Very cool space with tours and samples.

I used to be a single malt guy, but prefer Westland now.

http://www.westlanddistillery.com/

I discovered Westland (both the peated and single malt) at Pie Bar ~3yrs ago (last time I was in your neck of the woods). I liked it so much I brought a bottle home with me!

[tetsuo111]

Finally took her to be weighed. This "estate" weighs several hundreds of pounds less than most sports sedans and coupes.

Front: 1620 lbs / 49.4%. Rear: 1660 lbs / 50.6%. Total: 3280 lbs.

Lightweight cars are good.

[E91WAG3N]

Originally Posted by tetsuo111

Finally took her to be weighed. This "estate" weighs several hundreds of pounds less than most sports sedans and coupes.

Front: 1620 lbs / 49.4%. Rear: 1660 lbs / 50.6%. Total: 3280 lbs.

Lightweight cars are good.

That's a lot lighter than I would have guessed, you're down to e36 and e82 territory.

Compared to stock you've reduced weight with seats, rear bumper bar, wheels/tires, possibly exhaust, right?