Robs E46M Street to Track Build

[robgill]

Work in Progress!!! Recreating my M3Forum build thread, gonna take awhile... After this quick intro I'll break the work I've done over the last 7 years into Engine, Suspension, Interior and Exterior detail posts to get it caught up to present day.

In 2015 after many years of E92M ownership I decided I wanted to get into an E46M. At the time I lived in North Bethesda MD. I found a local and clean 2002 with 128k from a local enthusiast and M3Forum member. It was basically stock. The day I picked it up!



I started with general maintenance including rebuilding the cooling system, VANOS, filters etc... Also had Rogue Engineering Install rear subframe plates and a TCKline Dual Adjustable suspension. Also added an RE Half Cage and Recaro SPG XLs so I could use a 6 point harness. Then hit the track! Local Summit Point, Lime Rock, Palmer and Watkins Glen. I kept it street legal to I could drive to and from the track.



In 2016 I moved back to NYC and got a bigger garage in The Bronx where I could really start to modify the car. I did a full engine rebuild with CSL box and full exhaust. Also dded a OEM CSL trunk and rear wheels.





In 2020 I picked up a second E46M that would be a dedicated street car (Rosso M3). This let me start to move this car to more dedicated track! No more street compromises.



It didn't get much love in 2021 as I was focused on the street build but still managed a few track days. Most recently Watkins Glen in October 2022. With the Rosso car basically now done, there is a lot I plan do now do on this car including suspension upgrades and some exterior updates. More to come!

[Sharocks]

I see a Clubsport wing?

Looks cool!

[Onefastsicilian]

rob, you need to share some engine bay pics and your motor build.. this thing is a beast!

[robgill]

I see a Clubsport wing? Looks cool!

Yep! One of my recent updates. Will add more detail in my exterior updates post.

rob, you need to share some engine bay pics and your motor build.. this thing is a beast!

Thats gonna be the first post I recreate!

[robgill]

Engine Updates from 2015 to Present.

When I picked up this car I knew the first thing I wanted was a CSL style airbox. In 2016 I joined an M3Forum group buy for an Evolve box and started my S54 modifications.


I went with a TTFS CSL tune with a converted HP DME. I also installed Fabspeed headers and catless section 1.


Those modifications got me to around 320 WHP.


I ran this setup for about a year until two unfortunates events. First, after moving back to NYC I found out that the CSL tune can not be read by NY inspection. Second, the motor started overheating while I was on the track at NJMP. I suspected a blown head gasket, so in the winter of 2016 I decided to pull the head. Fortunately it wasn't the head gasket. Unfortunately it was a piston failure... The ring landing on piston 2 had cracked and the extra friction/heat had damaged the piston and head.



So decided to do a full engine rebuild. Which was an adventure....

[robgill]

Hold for engine rebuild history

[robgill]

Hold for exterior and interior update history

[robgill]

Hold for suspension update history

[robgill]

Haven't been motivated to get previous posts recreated so created some place holders. In the meantime I did a ton of work on this car over the winter, so lets get to recent updates! The last major suspension refresh on this car was in 2016. So after 6 years and a TON of track time I decided to do a full refresh this last winter. The car was setup for dual street & track duty so I was conservative in 2016 with the suspension bushings/springs/etc. Now that the car is basically track dedicated I wanted to go full bearings and solid bushings. I also have spare freshly powder coated subframes and trailing arms that came off the Rosso car, so able to get a lot of this done off the car in advance of dropping the subframe. Quick parts list for the refresh:

• Turner solid rear bushings
• Turner Monoball RTAB
• Rogue Engineering race rear camber arms
• Rogue Engineering 94A Diff Bushings
• Rogue Engineering outer (rebuilt) and inner control arm spherical bearings
• New OE hubs and bearings
• Puretech Sweden upper subframe/shock tower brace
• New TCKline springs 500# front 600# Rear

First I got the spare parts all powder coated including brackets, braces etc..



Old subframe coming out. Im getting very efficient at this...






Also rebuild all the RE bearing that were already on the car. Very easy and well designed by Ben at Rogue. Got new bearings from Summit Racing:



Used my new HF press to get all the bearings/bushings installed. Should have bought one of these years ago, makes this all so much!!



Done!



Almost back together! I stuck with my current TCKline dual adjustable dampers and upped the spring rates to the highest he recommended (500/600)

[robgill]

I also updated some body work over the winter. Both original fenders were a little banged up and also decided I didn't love the vented hood look. So new hood and fenders! It turned out the cheapest and most convenient way to order these parts was from Schmiedmann in Denmark. Even with the shipping costs it was still cheaper than anything domestic. I had them hold the parts at UPS and picked them up with a UHual trailer! I considered aftermarket CF fenders/hood but honestly care too much about fitment. So stuck with OE.




Old parts off the car:


New parts on! Not easy installing a hood by myself but managed to get it done without damaging anything...



Everything fit really well without much adjustment. Finished it all off with some basic engine maintenance, valve adjustment/plugs/oil/etc! Everything looks good.



With it all back together it was time to head over to Ivans for an alignment. He has fist come first serve on Saturday morning and it basically turns into a Cars & Coffee with everyone trying to get their track cars back together 😂. First impressions of the new setup are great. Looking forward to getting on track this month as soon as I can get the whole car vinyl wrapped in a new color next week!!!

[Exclusivs]

Nice updates Rob! Always dig following along here. And gaining some motivation for projects. Keep up the good work!

[robgill]

Got the wrap done! Originally wanted to go with British Racing Green but the local shops were out of stock and couldn't source the color. So went with my second choice Nardo Grey! Also has the front bumper PPFed to try and hold up better on the track. Wrapping the wing was overly complicated so I decided to just get that painted gloss black to match the rest of the trim.

[02_lsb]

Two money pits?!? You’re a hero.

[robgill]

New diff finally arrived after a 3 month wait. My old diff needed a rebuild and decided to go all in with a new one.

I went with a 3.85 gear, 3 Clutch 35/60 Ramps & REM® Polishing.



Would have been nice to have this when I rebuild the subframe but the timing just didn’t work. I needed the track car out of the garage so I could work on Rossos SMG to manual conversion. Unfortunately that is still in progress so I had to drop Rosso back onto it wheels and squeeze the track car in to get it in the quickjack and swap the diffs. Need my core refund and track day at line rock next Tuesday!



I need a bigger garage 😂

[usdmej]

what's it like owing two of the same cars with different tuning philosophies? do you ever drive one and wish you were driving the other or is it vice versa?