[ucsbwsr]

Originally Posted by Redshift

The wagon was an AWD car and had a totally different ABS/DSC hardware and software setup so the hard lines from the wagon body wouldn't insert (different physical size) and the module could not be properly coded to a RWD/335d setup so everything had to get switched.

I see, totally overlooked that original wagon was AWD. I had the same issue with my RWD conversion, not only did the RWD DSC have the ports in different locations but also the fittings of different diameters. It made no sense.

I was relocating my DSC from the engine bay behind the passenger headlight to just under the master cylinder behind the driver wheel liner which was the OEM M5 DSC location buuuuut, you guessed it, the M5 DSC pump had ports and fitting sizes different than RWD 535i so custom brake lines were made.

For more advanced coding I need to rely on my crutch and coding wizard, Levan. We did have some issues with my E61 accepting the coding/VIN since regionally there were no RWD E61s imported into the US. I don't recall exactly what we did in the end to side step it but we got it to work!

Evan

[Terraphantm]

Originally Posted by Redshift

The wagon was an AWD car and had a totally different ABS/DSC hardware and software setup so the hard lines from the wagon body wouldn't insert (different physical size) and the module could not be properly coded to a RWD/335d setup so everything had to get switched.

What's unknown is whether the system would have been the same if the wagon had been RWD.

A RWD wagon likely would have come with the correct module/wiring. Different coding, but nothing that couldn't be taken care of with NCS

[Redshift]

Originally Posted by Terraphantm

A RWD wagon likely would have come with the correct module/wiring. Different coding, but nothing that couldn't be taken care of with NCS

Right. A RWD wagon is a better starting point because of that and the transmission tunnel but that’s about all. The conversion of ABS/DSC only took maybe 2-3 hours with being careful and with the entire build otherwise already done. 2/3 of that time was re-pinning the connector which, as you’d expect, was totally incompatible with the module itself.

[jpwfranks]

Such a sweet build! Thanks for posting so much detail!

[coz_mo]

Epic build!

I might have missed it, but how did you end up handling the rwd transmission cross member on the XI chassis?

Any other differences/challenges you came across? Rwd front subframe bolts right up?

[Redshift]

Originally Posted by coz_mo

Epic build!

I might have missed it, but how did you end up handling the rwd transmission cross member on the XI chassis?

Any other differences/challenges you came across? Rwd front subframe bolts right up?

Custom bracket. Will post pictures when v2.0 is installed but right now the mock up is horrible looking.

[8081M]

So freaking awesome.

[Redshift]

Some big updates --

When you're the guest speaker at your local BMW CCA meeting and want a cool background for the Zoom call, you do this:



Finally got the spacers worked out -- ended up going with 5mm front and 12mm rears and they fit perfectly with the widened fenders.





Also, you can't tell in the photos but I had nicer tint installed (the stuff from San Fran was garbage) and also while it was there, had the entire front end, A-pillars, rocker panels, and entire rear bumper covered in self-healing PPF for protection. The tail lights were also tinted but they're too dark so it's going back for a much lighter version. I wanted it very subtle but this is way too dark.

Finally took her out for several drives and took some nice photos. More of those will definitely be coming. Right now it's getting the tune and coding finalized so I should have it back soon.

[RNByrd3]

Lovely! Am I mistaken, or did you not use M-sport side skirts?

[PostModernHero]

Originally Posted by Redshift

Some big updates --


Finally took her out for several drives and took some nice photos. More of those will definitely be coming. Right now it's getting the tune and coding finalized so I should have it back soon.

AMAZING!!!

[Redshift]

Some fairly final updates for the moment --

The car is almost fully sorted now. After deleting ACC, the only thing not working properly is cruise control. Everything else works as it should and there are no lights on the dash:



Through Mike at BPM Sport in California, who is doing all my coding work, we were able to upgrade the wagon's original TCU unit to a COMBOX and wire it in and get it running properly:



Here are just a few fun shots we grabbed while out for a drive with Nick (E46 M3) who did all the wiring and helped with most of the build (don't worry - I disliked the tail light tint so it has since been removed):

[Redshift]

Originally Posted by RNByrd3

Lovely! Am I mistaken, or did you not use M-sport side skirts?

Did not. Didn't see a big advantage or reason to spend so much money on them. Maybe a future upgrade.

[RNByrd3]

Originally Posted by Redshift

Did not. Didn't see a big advantage or reason to spend so much money on them. Maybe a future upgrade.

I was able to score some used ones from a salvage yard for just over $100 for the pair. I then just had to have them painted. They honestly don't make a huge difference to the look, and not many people would even know unless they know exactly what they're looking for.

[PORTMOODY]

amazing build from a to z. colour combo, interior all of it.

[Redshift]

Weighed the car tonight for an upcoming online feature article. Interestingly it was almost 50/50 weight distributed from both front to rear and also side to side. This was with the fuel tank almost empty and without me in the car.

[PORTMOODY]

Originally Posted by Redshift

Weighed the car tonight for an upcoming online feature article. Interestingly it was almost 50/50 weight distributed from both front to rear and also side to side. This was with the fuel tank almost empty and without me in the car.

A full tank is probably about another 130lbs. Thats about 3800lbs for a loaded car. Seems light given that its a wagon as well. I'm pretty sure my deleted car with DEF tank removed is about the same weight.

[Mike_Smith]

A couple quick questions about the gearbox / clutch setup.

I see you went with the HGK code transmission. Scouring eBay the HGU and HGD code trans seem much more plentiful. HGD has the old-style input shaft, HGU the new-style, but I haven't been able to find much discussion about other differences between them other than some oblique comments about different input shaft lengths.

Was HGK the only option, or did you just wind up with it by chance?

[edit: further research suggests that the HGU code superseded the HGK code; it's not clear when but HGU is listed as the replacement part for all pre-LCI 330d manuals]

Secondly - I can *almost* read the number off your clutch in the photos. You mentioned elsewhere (and Jim Kassel has commented as well) that the single-mass unit is super noisy, but I'm looking at this for a racing application and (probably) don't care. Would you be willing to share the flywheel / pressure / friction part numbers?

TIA - your build has been super informative, and your attention to detail is nothing short of amazing.

[Redshift]

Originally Posted by Mike_Smith

Was HGK the only option, or did you just wind up with it by chance?

Would you be willing to share the flywheel / pressure / friction part numbers?

TIA - your build has been super informative, and your attention to detail is nothing short of amazing.

HGK was what was suggested as "the proper fit" from Dennis @ Schmiedmann. He personally drives a 330d and was already very familiar with what I was attempting to do when I first reached out, so I put my trust in him and went with what he suggested. Don't look a gift horse in the mouth I say. It was reasonably priced and with everything else I ordered, shipping was virtually nothing and I got great help with the purchase so it was worth it to go with what he said would work.

I don't have the flywheel/pp/clutch part numbers but you can get those from Bimmerworld directly. Speak to Phil Wurz, the sales manager, about the setup. In fact, if you are seriously considering it, I may be boosting my power quite a bit which will require a different setup, so I'd be willing to sell you my very barely used setup and buy the upgraded stuff instead.

Thank you for your nice comment.

[whyzee125]

Wow!

[Redshift]

Just wanted to share the custom-made transmission adapter that my buddy Stephen made out of 1/4" steel. We powdercoated it to make it pretty but this is how it converts the AWD transmission tunnel to work with a manual/RWD transmission.

[dude8383]

Thats a smart and simple approach!

[BB_cuda]

I know you have spent a ton of money but see the picture I attached. I did this on my 335d sedan. It will bolt right up to our 335d rear subrame. I found them in a salvage yard for cheap. $100 for the pair. New they are available at $185 per side but require M3 specific rear struts.