[tetsuo111]

Last Updated May 26, 2021

This is my second E91 wagon.

The first, a 2011 E91 xDrive Steptronic, was wrecked after being T-boned on the Interstate. I considered a different replacement, but always returned to the E91. As a city-dweller limited to a one-bay garage, we need some practicality, so a pure toy like a M2 / C8 Vette / Lotus / Cayman won't work for us. The things I loved about my old E91 continued to attract: compact car dynamics, BMW balance, relatively cavernous interior, and discrete styling. I like the attention these long roofs attract from car enthusiasts. I'm also a fan of 'interesting' cars with potential for sleeper upgrades. IMO, the E91 is one of the finer compact touring packages available.

I took delivery of my new E91 on August 5th in Mountain View, CA. This sample was THE one, with only 35k one-owner miles, including complete service documentation from the OP's local BMW dealership, black sapphire metallic with Oyster leather interior. The OP ordered the car new from his local dealership, configured perfectly as a driver's car with ZSP / 6MT / RWD and no iDrive. The car was to be his daily, but the owner switched to a hybrid commuter, and the E91 sat unused in front of his home. I paid a lot for this car, and have no regrets whatsoever. I smile each time I'm behind the wheel.

I planned on breaking up the 13 hour return drive from Mountain View, CA to Seattle, WA over two-days, with a stopover in Bend, OR. Instead, I and the car felt terrific and just kept driving until we were both in my driveway at 10:30 p.m. 13 hours of driving on heavenly roads through beautiful scenery is enough time to form first impressions, comparing my former AWD AT wagon with the new-to-me RWD 6MT ZSP package.

Comparing E91s:

- 6MT vs 6AT Gearbox. It's widely accepted that modern DCTs, and now even high performance automatic transmissions, are easier to operate and faster changing gears compared with a manual. Still, I love the engagement, control, and proficiency that comes from rowing your own. Like driving older 911s, the argument for MT over AT is simple - superb analog feedback and driving pleasure.

- RWD vs AWD. Simple. xDrive has higher thresholds of grip and traction. xDrive is more stable and planted. RWD demands more attention and can bite, especially with hard RFTs entering damp, oily on-ramps after a light rain. RWD BMWs are tons of fun, using the right pedal to steer the rear or drift / hoon.

- Steering. At one point last year I was on a mission to swap steering racks because the 18:1 xDrive steering ratio felt slow. This car has the non-M RWD 16:1 rack. It's an upgrade in terms of feel and feedback. If you have ever flown aircraft, you know the feeling after trimming the control surfaces. The pilot can step back from the controls, and the aircraft will naturally return to a neutral, stable state. That's how this rack feels to me. I don't think the ratio is the cause, rather that RWD and xDrive front suspensions are entirely different, and this includes the steering rack and suspension geometry. The weight over the front is different, too.

- Final Thoughts. The cars look similar, but have different personalities. The first car was very capable and fun. I used it at the track and enjoyed her tremendously. I also learned how to work on the xDrive platform. But the car always felt like I wanted 'one more upgrade'. This car feels light and agile in a way that differentiates it from the old car. Sadly, I still feel like it's 'one more upgrade' away from being finished....

Problem:

BMWs from the Golden era between the 70s - 00s, were compact, lightweight, and balanced, earning a reputation as remarkable handling sedans with high specific-output, high-revving, naturally aspirated motors. Think 2002, 3.0 CSL, E30, E36, E46, M1, Z4M, 1M, etc. These cars were legitimate 4-door alternatives to Porsche, and put BMW on the radar for driving enthusiasts. Modern Bimmers are brutishly powerful but huge, heavy, and isolated from the road.

Solution:

This is my vision of an "E91 Club Sport". Imagine a semi-modern car with classic BMW attributes like 1) high-revving NA motor, 2) superior steering feedback, 3) lightness optimized for performance and agility, 4) driver-centric cockpit and instrumentation, and 5) discrete appearance.

Colin Chapman famously observed, "adding power makes you faster on the straights. Subtracting weight makes you faster everywhere." 300 crank HP is unremarkable in today's context, but it's enough to make smiles. Consider that for most drivers, a 300 hp wagon is too much car to pilot at the limit with proficiency.

For those who argue this is a wagon, not a Lotus, consider that in its present form, this E91 weighs almost 900 lbs less than a G80 M3! The weight to HP is superior to a E90 335i and a F22 M235i, and around the same as a Porsche Cayman. Bonus: wonder why motorcycles are so fast compared to cars? Just see below:


SPECS

- 2011 E91 328i RWD 6MT, 35k one-owner miles

- WEIGHT: 3200 lbs w/ half tank, no driver

F: 1600 lbs / 50.0%

R: 1600 lbs / 50.0%

RIDE HEIGHTS: (w/ half tank):

- Target heights = M3 ZCP (adjusted for 17" rims):

Front @ 587mm, Rear @ 571mm, +/- 10 mm (Measured from bottom of rim up to lower fender arch)

- Actual heights = Front @ 588 mm Rear @ 568 mm

DELETED OPTIONS:

Editions and Packages:
- S704 M Sports suspension

Comfort and Interior Equipment:
- S4AB Fine wood trim burl walnut
- S459 Seat adjustment, electric, with memory
- S481 Sports seat
- S488 Lumbar support, driver and passenger
- S494 Seat heating driver/passenger

Multimedia:
- S639 Preparation f mobile phone cpl. USA/CDN

Driver Assistance and Lighting:
- S520 Fog lights (no fogs for M-Performance bumper)

Wheels and Drive:
- S2S1 BMW LA wheel star spoke 286
- S2VB Tyre pressure control (TPC)
- S249 Multifunction f steering wheel
- S255 Sports leather steering wheel

Environment and Safety:
- S840 High speed synchronization

Other Equipment:
- S992 Control of number-plate attachment


MODS:

CHASSIS:
- Solid rear subframe (Turner AL bushings)
- M3 front chassis thrust panel + billet Al stiffening rods
- M3 front strut tower brace
- M3 rear chassis underbody stiffening rods
- M3 rear chassis stiffening plates - wheel arches to body
- M3 engine cowl
- M3 carbon Kevlar front bumper bar (-10 lbs)
- Euro 330i rear bumper bar (-12 lbs) . Euro 330i Bumper Bar

TUNE: STAGE FP / BPC
- Redline 7000 -> 7500
- MILVs
- Headers - Offroad
- 3" intake snorkel
- TPS remap
- Top speed de-limit

WHEELS & TIRES:
- APEX ARC-8 17x9 ET:30 (16.5 lbs / ea)
- Street tires: Bridgestone Potenza S-04 255/40/17 square
- Track tires: Bridgestone RE-71A 255/40/17 square
- Stud conversion (MSI)
- 19 mm lugs (Turner)
- Enable FTM -> Delete TPMS TPMS Delete -> FTM On

BRAKES:
- M3 STOPTECH TROPHY ST40R 355mm / 355mm
- PFC 11 / PFC 08
- SS brake lines

FRONT SUSPENSION:
- M3 Nitron R3 + piggyback reservoirs
- Hyperco springs 457 lb/in - Wheel rate @ 421 lb/in
- M3 wheel carriers / spindles
- M3 hubs & bearings
- M3 control arms with SYNCRO (sp) DESIGN WORKS sealed monoball bearings SYNCRO DESIGN WORKS Monoballs
- DINAN 32mm hollow adjustable anti-roll bar and links

REAR SUSPENSION:
- Solid rear subframe (Turner AL bushings)
- True coilover rear suspension conversion
- M3 Nitron R3 + remote reservoirs
- Hyperco springs 350 lb/in - Wheel rate @ 241 lb/in (Equivalent to 717 lb/inch springs in standard divorced configuration)
- M3 wheel carriers / spindes
- M3 hubs & bearings
- M3 control arms
- M3 toe arms (Bimmerworld)
- Sealed monoball lower camber arm bearings (Bimmerworld)
- 19.2mm solid ARB (UUC)
- Endlinks (AKG)

INTAKE:
- BMW 3-stage DISA intake manifold
- CYBA scoops w/ Cerakote
- M-PERFORMANCE Euro Performance Intake.
- AFE Pro Dry conical filter
- HENDRICK MOTORSPORTS 3" CF snorkel
- REV MOTORSPORTS silicon coupler tube

VALVETRAIN:
- MILVs

DRIVETRAIN:
- 50A solid rubber motor mounts (034 MOTORSPORTS)
- OEM E30 trans mounts
- Delrin diff mounts (Turner)
- SSK - 30% reduced throw (AutoSolutions).AutoSolutions SSK and CDV delete
- CDV deleted

EXHAUST: Dundon Motorsports Exhaust
- Headers + Ceramic thermal barrier (Supersprint)
- Test pipes - 2nd Cats delete (Supersprint)
- Custom 3" 20 Gauge 321 SS aerospace alloy + Inconel exhaust (-40 lbs) DUNDON MOTORSPORTS https://www.dundonmotorsports.com/

ELECTRICAL:
- VOLTPHREAKS VPH900 7 Lb, 33AH, LiFePO4 Battery . LiFePO4 Battery Install
- Billet AL Battery Box
- CTEK Lithium US charger

COCKPIT:
- RECARO Profi + PLANTED seat brackets (-70 lbs)
- MOMO Prototipo 6C 350mm CF steering wheel + MOMO hub adapter 2013 + BMW 41mm roundel #46542300045 . MOMO Prototipo 6C
- M3 Kombi
- M3 center console
- M3 GTS Alcantara armrest
- M3 shift insert
- M3 carbon fiber leather trim
- M3 cabin microfilters
- ZHP 6MT weighted shift knob . ZHP Weighted Shift Knob Install
- M Sport door sill
- Ultimate Clutch Pedal . UCP
- UUC billet E-brake handle
- LeatherZ Alcantara shifter and E-brake boots . LeatherZ Alcantara Shifter and E-Brake Boots
- TURNER MOTORSPORTS billet Al pedals
- 3M non-slip clutch & brake pedals
- Rear seat + privacy screen delete (-85 lbs)
- Safecraft PC2 / Halon 1211 fire extinguisher and Brey Krause bottle mount . Safecraft PC2 / Brey Krause
- 335i Euro E91 luggage trunk floor
- Thinkware F800 Pro Dash Cam

EXTERIOR:
- M PERFORMANCE Aerodynamics Kit (front / rear bumpers, rockers, CF splitters, cooling)
- M PERFORMANCE grills
- Seibon hood, Quik-Latch pins
- XPEL Prime XR 35% tint
- Body colored side reflectors

LIGHTING:
- BMW Euro tail lights w/ amber turn signals
- PHILIPS X-treme Ultinon H7 LED Hi and Lo beam headlamps
- LED reverse lights
- LUX AE rings


August 5, 2017 - Picking-up the Unicorn in Mountain View, CA:

[tetsuo111]

Every story has a beginning. This is mine...

First picture on the evening before she was wrecked. The other pics are self-explanatory.

[tetsuo111]

Similar but different. 328iT ZSP 6MT RWD.

Lot's to do!

This project feels less methodical than my last, mostly because of the random build sequence. Rather than my preferred order of precedence, I'm taking the parts salvaged from the old car and moving them to this car.

IME, the proper build order is logical and sequential:

1) Tires and wheels
2) Chassis
3) Brakes
4) Suspension
5) Power - aesthetic - other - misc

In this case, I'm installing bits and pieces as they're available and circumstances permit.

[tetsuo111]

I've finished a few mods since taking delivery. Most of them involved transferring parts salvaged from the old car.

INTERIOR
- Recaro Profi seats
- M3 steering wheel
- M3 GTS-style alcantara armrest delete
- M3 carbon fiber leather trim
- AutoSolutions 30% SSK
- UUC billet emergency brake handle
- 3M non-slip replaced rubber pedal covers. The first wagon had Turner AL pedals. 3M non-slip tape functions much better!
3M non-slip pedals

BREATHING
- Cyba intake scoops + Cerakote
- Rev Motoring silicon TB hose
- Dundon Motorsports 3" 20G Inconel / 321 exhaust + Vibrant 1132 resonator + Coast Fabrication suppressor + SuperSprint test pipes

CHASSIS
- M3 strut tower brace
- M3 rear chassis braces + E91 rear chassis brace delete

OTHER
- M3 cowl + microfilters
- CDV delete CDV delete

EXTERIOR
- Lux AE/blk grills

[Hobbs64]

That is a beautiful clean car! what seats are you running? Can you post a pic of the seats? They look at home in that car from what I can see.

[BrandJas18]

Sad to see the original car was smashed, but I am glad to see its been replaced and you will have a great car as you continue to mod it.

[tetsuo111]

Originally Posted by Hobbs64

That is a beautiful clean car! what seats are you running? Can you post a pic of the seats? They look at home in that car from what I can see.

Thanks. They are Recaro Profi SPG shells.

Here's a picture of them in the old car:

[tetsuo111]

....to see the autumn colors.

[ObsidianX]

Look forward to seeing the pics of your touring among the fall colors!

[tetsuo111]

Just some pictures I took yesterday. The autumn colors are irresistible...

The Walnut wood center console has been replaced with a M3 Novillo black leather part and shifter. I just need to install the leather storage cover to complete the job. The 3M non-slip tape on the clutch and brake pedals is proving to be one of those seemingly trivial mods that is surprisingly satisfying to use with every session behind the wheel. I much prefer the 3M tape to the aluminum pedals I was using.

Finally got around to installing my DISA 3-stage intake manifold last weekend. Second time around was a breeze with the benefit of prior experience and support (thanks Jonathan!).

I had my old hyper-black Apex ARC-8's re-finished at Complete Wheel Repair earlier this week, and an appointment scheduled to mount them on the car later today.

Tomorrow the car goes in for Xpel Prime XR window tint. Suggestions on 25% v. 35% light transmission? I want to avoid the "black car with dark limousine widows" style, so leaning towards the 35%.

[chau]

Nice wagon. Regarding tint, if you're going to track often then probably 35%. I've had safety officials at track days question the tint on my 240sx.

[tetsuo111]

Thanks for that. Yet another strong argument to follow my gut. Certainly want max visibility in a track environment.

Originally Posted by chau

Nice wagon. Regarding tint, if you're going to track often then probably 35%. I've had safety officials at track days question the tint on my 240sx.

[NYBulldog]

Nice dude. I want to see it the ARC8. Hurry up!

[tetsuo111]

Originally Posted by NYBulldog

Nice dude. I want to see it the ARC8. Hurry up!

Ask and you shall receive.....

I'm still a big fan of the ARC-8s, but to my eye they don't work as well with the black car as with the old deep sea metallic blue. It seems like something's missing.

They're only on the car for a couple of hours today so I may just need to get re-acquainted with them.

I stopped on the way back to have a small rock chip in the windshield repaired. Naturally the shop made the crack larger and advises installing a new replacement windshield. Argh!

[NYBulldog]

Originally Posted by tetsuo111

Ask and you shall receive.....

I'm still a big fan of the ARC-8s, but to my eye they don't work as well with the black car as with the old deep sea metallic blue. It seems like something's missing.

They're only on the car for a couple of hours today so I may just need to get re-acquainted with them.

I stopped on the way back to have a small rock chip in the windshield repaired. Naturally the shop made the crack larger and advises installing a new replacement windshield. Argh!

Looks great man. I agree, that color doesn't have the same pop on this black one as on the blue. But lower it first, always makes a huge difference. As much as I hate black wheels, I'd say gloss black or just regular bright silver gloss would look a bit better. Damn shop!

[NYBulldog]

Yup, just lower it.

[tetsuo111]

Originally Posted by NYBulldog

Yup, just lower it.

Mad skills!

I noticed at least 3 edits to the original picture:

- lowered
- front BBK
- front bumper amber reflector painted body color

Are there any other edits I missed?

Thanks for this! Your editing skills are respectable and the visualization helps to focus for future projects.

P.S. Now, if you would just conjure / photoshop an S65 into reality we can call it a day.

[tetsuo111]

Had the windows tinted today with Xpel Prime XR 35%. Niel (the owner) and his team at NW Autoshield were a pleasure to work with.

The last car (dark blue) had 30% tint. With this car's black paint, the slightly lighter tint is a better match to my eye. In real life, the tint appears lighter than in the picture. The sky was gray and overcast today, making it difficult to accurately capture the different color tones.

[E91WAG3N]

Great build, really sorry to hear about your old car, but glad you came out ok. I enjoyed watching the progress you made with it. Glad to see your new car went to a good home, I saw it pop up for sale a couple months back and considered it for a minute.

What are your future plans? The BBK you had on the old car would really pop on Black Sapphire and might give your ARC-8's some more visual appeal.

[NYBulldog]

Originally Posted by tetsuo111

Mad skills!

I noticed at least 3 edits to the original picture:

- lowered
- front BBK
- front bumper amber reflector painted body color

Are there any other edits I missed?

Thanks for this! Your editing skills are respectable and the visualization helps to focus for future projects.

P.S. Now, if you would just conjure / photoshop an S65 into reality we can call it a day.

lmfao we all want the S65 photoshop. Yup, 3 simple mods. I was gonna go nuts with the Perf bumper and what not but on a quick look up there were no good pics in black at that angle. I can't wait to see how this evolves.

[tetsuo111]

Thanks for that ubersteuer.

Future plans? Good question...

Exterior:
- install M Performance Aero front and rear bumper covers and rocker panels
- replace cracked driver's side mirror with M3 side mirror
- paint correction and Xpel / clear bra

Interior:
- mostly done with a few outstanding projects like center console storage tray cover and maybe a new steering wheel

Exhaust:
- install SuperSprint headers

Brakes:
- install BBK

Originally Posted by ubersteuer

Great build, really sorry to hear about your old car, but glad you came out ok...

What are your future plans? The BBK you had on the old car would really pop on Black Sapphire and might give your ARC-8's some more visual appeal.

[tetsuo111]

In over 20 years, the weather has never been so amazingly pleasant. Last summer was extraordinary, with clear blue skies daily and almost no overcast days, let alone rain. Well we did have a lot of hazy air resulting from the fires, but that's a different story... Now, halfway through October, it's more of the same perfect weather. Will it never end?

And it keeps getting better - first snows are already falling in the mountains.

We're prepping for the upcoming winter fun season, organizing gear, waxing boards, changing batteries, and just waiting a little longer for the base to form above 5k ft, so we can get out for the first tracks of the year. If you look closely at the horizon in the second picture, you can see the 14,411' summit of Mt Rainier poking out and calling.

Lol, already dreaming about snow, and the Wx is flawless outside....