Cockroach Individual M3 6/2 AST DIY, 70C Thermostat

[samthejam]

Hey Guys, wanted to document my new to me M3 build here.

I am a long-time E28 enthusiast. I have a 528e that is my first car, a track/street hybrid I built. It's had many M30s put in it, dogleg transmission, diff I built, coilovers, all spherical bushings,. However it still has A/C, cruise control, and a niceish Mocca cloth interior I imported from Russia before covid so it is somewhat palatable on the street. I put 20,000 miles on it last year, taking road trips to tracks like Road Atlanta and Barber. It then takes me back home and then to work the next day. It isn't shiny, but it's loved, enjoyed and a long term money pit.

Cockroach First Upload by Kurvenkamph Motorsport, on Flickr
382236441_2674085969434972_3752035176532954767_n by Kurvenkamph Motorsport, on Flickr

Build Thread here:

https://www.mye28.com/viewtopic.php?t=126811

I had a M535i that I had for about a year but never fell in love with.

Build Thread Here:

https://www.mye28.com/viewtopic.php?t=159736

The opportunity came to trade that car for this E46 M3. I jumped on it. Here is the story so far.

My friend Alejandro picked this car up for a song. A 2005 Individual "Black Sapphire Metallic" Coupe M3. It was loved at some point has a Vorsteiner Carbon Trunk Lid, real carbon diffuser, carbon interior trim bits, carbon for the engine cover. It only has the KW rear springs and perches for some reason. It was also fairly low miles 101k.

Cockroach First Upload by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr
Cockroach First Upload by Kurvenkamph Motorsport, on Flickr




With the prices of S54s and these cars going through the moon, I decided to just do it. My father had one from new that I used to drive on track and drove around the paddock when I was like 13. So these cars especially their engines and sound are very emotional to me.
Cockroach First Upload by Kurvenkamph Motorsport, on Flickr
Cockroach First Upload by Kurvenkamph Motorsport, on Flickr



It was parked because the SMG line to the slave cylinder failed. He had spares from parts cars, he just built a E46 Touring with a S54 swap and parted out 3 M3s to do that. So he had some spares. Prior to that failing, the cars horrific wheels that were on it were so heavy and with Houston roads obliterated the front ball joints. So much so they drove it until it failed and damaged the left front fender. They then only fixed that side with the right side being about to fail.

Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr

He was able to get the car, and just had a shop diagnose the SMG and bleed the system. I joked with him about trading and then it became a reality. Now before I could drive the car the wheels had to go. So we did that. I then took it on a long test drive 20 miles as is, balljoints shaking. Hadn't touched fluids or anything. Needed to verify the car had decent bones to be a rolling restoration I needed. My M535i, I had it to where it was a turnkey spare car with A/C. So if I were to do this trade, I need to at least know if my E28 is down I can get in this and get to work. It passed the test and he agreed to include a lot of used bits the car needed to be more complete.

Cockroach First Upload by Kurvenkamph Motorsport, on Flickr
Cockroach First Upload by Kurvenkamph Motorsport, on Flickr
Cockroach First Upload by Kurvenkamph Motorsport, on Flickr

I then went to Road Atlanta, the following day upon my return. I got to work. I swapped the bad control arm out with a used one and got a front bumper on the car and took it home.

Cockroach First Upload by Kurvenkamph Motorsport, on Flickr
Cockroach First Upload by Kurvenkamph Motorsport, on Flickr

Once I got it home, I did an oil change. Luckily the dealer had a filter and Autozone had some Castrol 10W-60. I am a bit sad to see the old TWS oil I remember using to top off my dads car is no longer available. I read the specs of this oil and it appears to be the same as the old stuff. Will probably just stick to running this since it is available locally.

Cockroach First Upload by Kurvenkamph Motorsport, on Flickr
Cockroach First Upload by Kurvenkamph Motorsport, on Flickr

I found taillights from a ZHP Coupe, that I could actually look at.
Cockroach First Upload by Kurvenkamph Motorsport, on Flickr
Cockroach First Upload by Kurvenkamph Motorsport, on Flickr

I put Halogens in the car, as the Xenons were fucked and these had the trims. Lost high beams doing that.
Cockroach First Upload by Kurvenkamph Motorsport, on Flickr

Alarm kept going off and tracked that down to the hood sensor missing its hardware. Cobbled something together from E28 hardware from some partouts.

Cockroach First Upload by Kurvenkamph Motorsport, on Flickr


I ordered the rod Bearings and the diff bushings, and was driving the car around. I went to visit my dad who is 80 miles away one way, and the fan decided to make love with the very very questionable shroud. Alejandro rescued me, AAA wouldnt come get me. So he flat towed me back to my dads like 20 miles. Gave me used parts to get me back on the road. That was a long night.

Cockroach First Upload by Kurvenkamph Motorsport, on Flickr
Cockroach First Upload by Kurvenkamph Motorsport, on Flickr
Cockroach First Upload by Kurvenkamph Motorsport, on Flickr
Cockroach First Upload by Kurvenkamph Motorsport, on Flickr
Cockroach First Upload by Kurvenkamph Motorsport, on Flickr

The next weekend, it was time to install the box of parts.
Cockroach First Upload by Kurvenkamph Motorsport, on Flickr

I planned to do the rod bearings, diff bushings and power steering pump in one weekend. It was a bit bold, as again the 3 hour round trip to my dad each day. I prefer to do it at his shop because A/C and he has a lot more tools, so it is worth the trek. Saturday was the diff bushing, which were FUCKED. It was making a horrendous noise, had car in S3 for the SMG and was doing some right footwork so it didn't sound like the diff was coming through the floor on shifts.
Cockroach First Upload by Kurvenkamph Motorsport, on Flickr


I was somehow able to press out and press in the new BMW bushing, didn't wanna go aftermarket for this. I pressed in too far and had to press it back. Can't wait for the foam to fail in 20 years.
Cockroach First Upload by Kurvenkamph Motorsport, on Flickr

You can see I opted for the E36 M3 diff bushings, instead of the OE/aftermarket ones. I still wish I would've gone with the OE cover, just because. However with all the parts being ordered at once it just wasn't in the budget.
Cockroach First Upload by Kurvenkamph Motorsport, on Flickr
Cockroach First Upload by Kurvenkamph Motorsport, on Flickr

I found a crack in one of the subframe mounts visible with subframe in. So this will all have to come out again anyways, will be doing everything at that time. At least this will make the car driveable for now to fix all the other stuff. So the diff took all day. I took my dads car home, so when I got back Sunday morning car wouldn't be hot and have to wait for it cool down to do the rod bearings.

I have owned this car for two weeks at this point, and am petrified of opening this thing up but it must be done.
I went with OE Bearings and bolts. Man that torque procedure is an absolute nightmare.

Cockroach First Upload by Kurvenkamph Motorsport, on Flickr
Cockroach First Upload by Kurvenkamph Motorsport, on Flickr

At first I was a bit upset I was in there doing it as it didn't look horrid. I then found #2.
Cockroach First Upload by Kurvenkamph Motorsport, on Flickr

Here is how they all looked.
Cockroach First Upload by Kurvenkamph Motorsport, on Flickr

New to me used pump.
Cockroach First Upload by Kurvenkamph Motorsport, on Flickr

I was able to finish it all in one day and drive home, didn't get home until midnight. Odo pick before heading home. I am doing the 1200 mile break-in which I know is controversial. I know rod bearings should never need to break-in as in theory they don't touch anything. However I don't see harm in being overly cautious with the cost of this engine. There is a also still a intermittent misfire and belt squeak. Those parts are on the way (coils, plugs and belts/pulleys).

Cockroach First Upload by Kurvenkamph Motorsport, on Flickr
Cockroach First Upload by Kurvenkamph Motorsport, on Flickr


I also phoned a local friend who helped me code my LCM for the Halogens, so I have highbeams again. Also put on the CSL firmware for the SMG with the ECUWorkz tool and flashed the SMG module with the 255 software. Following this I got INPA setup on my Windows XP laptop, also got it working in it English.

Currently waiting on maintenance parts listed above and I got some used GC coilovers off Ebay for it. I think I will try and find 2 more rear wheels and run that square setup until Apexes. Order of attack is bushings alignment, put SRF and pads in it, vanos and then rear subframe reinforcement/bushings.

Cockroach First Upload by Kurvenkamph Motorsport, on Flickr


Currently have 102,880 on the car. Currently have 522 miles on the break-in, hoping to hear this thing at 8k rpm soon.

Thanks for reading.

- Sam

[samthejam]

Also forgot to mention wired in and replaced the Ambient Air Temp sensor as that was causing CEL and intermittent climate control in wet weather.

[Tbonem3]

Welcome!

So was the mystic or topaz blue car pictured near the beginning your dad's when new? Very cool. Also cool your car is individual with black sapphire - hopefully the paint can be saved?

[samthejam]

Welcome!

So was the mystic or topaz blue car pictured near the beginning your dad's when new? Very cool. Also cool your car is individual with black sapphire - hopefully the paint can be saved?

It was a ZCP, so it was Interlagos Blue.

This car has been repainted quite a few times, so unfortunately nothing original really to save. I know it was at least repainted once for the CF trunklid. I found some very old Instagram post that showed the car that was in Primer on the quarter panels. The crinkled fender has bondo.

[0-60motorsports]

Welcome and awesome start. Love the color. Once you are done with it it'll look beautiful.

[Sharocks]

I think someone in the TX area had this car from the OG M3Fourm. I remember seeing it posted in a thread about individual cars. Happy to see it's getting some love!

[samthejam]

Looking at the Inspection History, it has been in Houston since 2009. Was able to dig this up, since it had a vanity plate for a short period. MPW3R baby.

Strasse Forged Wheels BMW E46 M3 by Strasse Wheels, on Flickr
Strasse Forged Wheels BMW E46 M3 by Strasse Wheels, on Flickr

https://strassewheels.com/case/bmw-e46-m3/

[Sharocks]

So I was correct lmao.

[samthejam]

All the parts came in so did some more maintenance. Looks like the pulleys and tensioners were all still original. Unfortunately someone had already changed the plugs with the wrong ones. New Eldor coils and OE plugs now.
Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr

Also got the coilovers on and hated how it looked with the staggered fronts and I accidentally put like 5 degrees of camber in it. That was dicey on the highway lo. I found someone selling a full set of rear wheels. It really wasn't that good of a deal have absolutely ancient RS4s of only two hold air, but it'll do for now. About to crest 1000 miles on the break-in. So it has even more mismatched tires, and now needs an alignment. Can't do that until I fix the shock towers. Both sides are cracked. It had 20 inch wheels in Houston for years and was on KWs at one point so that didn't do that sheetmetal any good. Also might as well replace the RTABs as well if I am going to get it aligned. So that is probably the next priority on the list. The used GCs feel okay can't complain for the price. Rear shocks are just OTS Koni Yellows and are pretty tired.


Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr


My friend had a E46 M3 Vert he is about to scrap. I noticed it did not have an armrest so grabbed all those pieces. Upon installing it I noticed there was nothing to secure the rear of the console, so had to go back to grab that bracket.

Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr

[samthejam]

Before I did Vanos, wanted to focus on some items for safety and some mods to make the car more enjoyable.

I needed new tires but didn't want to do it with alignment fucked or pay a shop to align it iwht the stock RTABs. So I replaced and added reinforcements since it's cracked. Really should've welded it but I will hold that until I do the rear floorpan. I cheaped out and got the Bimmerworld RTAB.

Untitled by Kurvenkamph Motorsport, on Flickr

Untitled by Kurvenkamph Motorsport, on FlickrUntitled by Kurvenkamph Motorsport, on Flickr

Following that got new Rs4s all around.
Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr

Probably last pictures of the wheels being clean ever. Because after that flushed the fluid out with SRF and put on some takeoff pads from my E28 PFC 11s. That car uses E34 M5 brakes so pad shape is the same.

Also the biggest mod was a Recaro Profi. This one is huge for me, I am pretty skinny and only 5' 5" so the stock seat is just terrible for me. So I am much happier being seated in the car now.

Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr

Just ordered a bunch of stuff for the vanos to prevent any catastrophic failures. (Addressing the cam gear bolts and exhaust hub next). Also doing the TrackCABs Bimmerworld. Trying to get the car ready for Road Atlanta in a month.

[samthejam]

Also all my notes/things that might be useful for anyone installing the Brey Krause seat bracket.

https://www.youtube.com/watch?v=D3bDXSGjlAw

[samthejam]

So after the seat I ordered almost all the Vanos parts needed to stop it from having a failure that would turn it into a paperweight. It took like 2 weeks for the parts to come in, from FCPEuro, Lang Racing and Beisan. I drove the 90 minutes to my dads shop and went to put the TDC tool in and was greeted with:

September Update by Kurvenkamph Motorsport, on Flickr

September Update by Kurvenkamph Motorsport, on Flickr

Why the bracket is gone, who knows. My guess it that this is another used engine has been swapped into this car, there were a lot of signs pointing to this. But regardless this left me SOL, and with 2 weeks remaining to RA. I just focused on resealing the valve cover, tabs weren't broken. So I was gonna have to chance it. If it was the original motor it has like 106k on it at this point so fuck it, I have to run it.

Torquing everything to the magical BMW numbers
September Update by Kurvenkamph Motorsport, on Flickr

At this point car was going brr, did the BW Trackcabs. Got it realigned again went for -3.5 front camber, was able to get -2 with stock rear arms which is perfect. Did 0 toe for the front and stock toe in the rear.

I also scored the BW Street/track exhaust used. The BW sound is very nostalgic to me from childhood, a bit much to deal with everyday but its tolerable. My E28 is very loud too. I do miss the torque lol, maybe an epic tune or hte or something will get it back. The AA exhaust I had on the car was turning itself into a pressure vessel, rattling and coming apart everywhere.



September Update by Kurvenkamph Motorsport, on Flickr

I also washed the car for the first time since buying it, sort've has paint.
September Update by Kurvenkamph Motorsport, on Flickr
September Update by Kurvenkamph Motorsport, on Flickr


Then it was time to hit the road to Road Atlanta. Everytime I do these trips, I cannonball from Houston to Georgia and meet up with my friend Jay in Atlanta. I believe he is lurking around on here but yeah drove there and brought some ear plugs. Seats had to be down since I was bringing Jay a section 2 exhaust. My vorsteiner CF lid, does absolutely nothing for sound deadening, it was LOUD.

September Update by Kurvenkamph Motorsport, on Flickr
September Update by Kurvenkamph Motorsport, on Flickr
September Update by Kurvenkamph Motorsport, on Flickr

Pretty uneventful, just a lot of driving did it in about 13 hours.

Got to his house and went to button up a lot of little stuff, just did another brake bleed, swapped in some thicker takeoffs pads for the rear and fixed the CEL. He had an extra purge valve on a S54 he is using to swap his E36 M3. So we threw that in, and that made my CEL go away.
September Update by Kurvenkamph Motorsport, on Flickr

Satuday was raining a lot. Gave some ride along and it was dicey learning the car there in the wet. Lot of oh shit moments coming down the esses lol but we lived. Gave some ridealongs as well. Only issue was the power steering was intermittently going out.

September Update by Kurvenkamph Motorsport, on Flickr

I worked black flag, so during a huge oil spill in which someone oiled down turns 12-1 was able to get a pic of the car on the hill while we figured out what we were gonna do.
September Update by Kurvenkamph Motorsport, on Flickr
September Update by Kurvenkamph Motorsport, on Flickr

Left the car at the track and came back Sunday to enjoy the dryer weather. Did a quick flush for the P/S, just sucked olkd fluid out of reservoir and put in new fluid to see what would happen and that fixed the P/S.

September Update by Kurvenkamph Motorsport, on Flickr
September Update by Kurvenkamph Motorsport, on Flickr

Finally started going pretty deep into the brakes into 10A, the turn signal noticed that.
September Update by Kurvenkamph Motorsport, on Flickr


Keep in mind my front shock towers are still cracked as well as the rear subframe, but it's all good though.

September Update by Kurvenkamph Motorsport, on Flickr

Also let Jay take it out

September Update by Kurvenkamph Motorsport, on Flickr

September Update by Kurvenkamph Motorsport, on Flickr

I was able to squeeze out a 1:40.98 which I am super happy with considering how basic the car is currently and I am still getting used to it. Should be an easy sub 39 car, especially on something saucier than the RS4s. Tires pressures were what I rolled up on as well, 30 cold. I think they were getting to 36 got.

September Update by Kurvenkamph Motorsport, on Flickr

Axle boot got a bit angry.

September Update by Kurvenkamph Motorsport, on Flickr

Unfortunately, I had go pro issues so was only able to get a 42 documented in video from earlier in the morning.

https://www.youtube.com/watch?v=8otm5PqYyaE

As far as modifying the car for further, the big thing is the brakes. I want to do the CSL/ZCP brakes just not happy with these especially going into 10A and T1. Just not very confidence inspiring. I remember my dads car stopped a lot better.

But yeah car did great, other than the power steering issue nothing really happened. The pace for the first time out in the car was fantastic.


I then drove home, only issue was the sunroof. It got angry trying to close from tilt position but got it shut at a gas station.

September Update by Kurvenkamph Motorsport, on Flickr

I have somehow put like 7000 miles on this thing in the last 3 months.

September Update by Kurvenkamph Motorsport, on Flickr


Following the trip took it to work for a week, and I finally have gotten to the point where I couldnt stand the fucking tint. So I spent like 5 hours removing it. I can actually see out of the car now!

September Update by Kurvenkamph Motorsport, on Flickr
September Update by Kurvenkamph Motorsport, on Flickr
September Update by Kurvenkamph Motorsport, on Flickr
September Update by Kurvenkamph Motorsport, on Flickr

Ordered the TDC bracket from the dealer, so I will resume the vanos stuff here shortly. As well as more maintenance items. The rear floorpan reinfocement is gonna be coming soon as well, think Im going the CMP route for reinforcing all that. All the welds and metal.

[samthejam]

Turn signal has some RS4 on it now.

September Update by Kurvenkamph Motorsport, on Flickr

[samthejam]

If you installed a messed up Oil Pump Disk spring you could end up like this:
Vanos and wheels by Kurvenkamph Motorsport, on Flickr


The spring cap fitment was already pretty horrendous but didn't want to oversand it, not to mention the fact I smashed the Vanos unit on the spring. Don't ask how. So idk what exactly caused the pistons in the disc to seize up. But anyways I had to do it again.

Vanos and wheels by Kurvenkamph Motorsport, on Flickr
Vanos and wheels by Kurvenkamph Motorsport, on Flickr
Vanos and wheels by Kurvenkamph Motorsport, on Flickr
Vanos and wheels by Kurvenkamph Motorsport, on Flickr
Vanos and wheels by Kurvenkamph Motorsport, on Flickr


First go around I did the Beisan upper guide, Lang Bolts and the Oil Pump disk. I put about 300 miles on it, and then was greeted to a cam'd idle at a stoplight. Vanos codes for both intake and exhaust. Not knowing what the hell happened, I sourced a new core unit to rebuild. same day upon failure. Got SUPER lucky with that, the shop I used to work had a S54 in pieces.

Vanos and wheels by Kurvenkamph Motorsport, on Flickr
Vanos and wheels by Kurvenkamph Motorsport, on Flickr

This time I learned my lesson. Don't rush it at my dads and just do everything.

I actually have access to a shop behind my house, but I feel bad leaving a car there overnight in case my landlord needs the lift. In this case though, there was no point in rushing. So I took my time and worked on the car on and off in the evenings for a week. Rebuilt the new unit with Beisan Seals, got a new solenoid pack, Vanos filter, and cleaned the solenoid block. Also did the Vanos line.

Take 2:
Vanos and wheels by Kurvenkamph Motorsport, on Flickr
Vanos and wheels by Kurvenkamph Motorsport, on Flickr
Vanos and wheels by Kurvenkamph Motorsport, on Flickr
Vanos and wheels by Kurvenkamph Motorsport, on Flickr
Vanos and wheels by Kurvenkamph Motorsport, on Flickr

Doing the seals restored a lot of driveability with the old girl, so glad I did the seals on the second go around. Learned a lot from this ordeal. I have put about a 1000 miles on it since then, one of the break in drives was to pick up the wheels.

So like I mentioned in my first post, I used to tag along with my dad to HPDEs at Texas World Speedway. The CDI there for PDS had a E46 M3 full racecar. He was paraplegic, so he had a SMG, slicktop E46 M3 it had Grand Am Motons, Stoptech 355mm brakes front and rear, badass cage, Fulcrum Aero which had a really good front splitter, huge rear wing that tied into the floor. He was a very good driver and the car was very sorted. It was built pre 2006, so a very OG build. On the car he had SSRs, I remember the car being stored at the track and the garage had a fuck ton of wheels in there with Hoosiers.

Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr

Long story short, when these came up on Marketplace I knew exactly where they were from. I was able to get all 10 for the same price as a set of New apex's. Biggest downside is only 4 were a matching set. One of which was cracked. The others were sets of 3s. All these are the same size. 18x9.5 ET35, yes they are old tired wheels used on a racecar with Aero and hoosiers and mismatched, but finding a nice pair of quality wheels these days for that little is hard. I also need spares since I drive the car around Houston, want to juggle sets of tires. I would like to get a set refinished to match but there are bigger fish to dry right now, the cracked one is cracked on the inner barrel so that should be no issue getting that welded. More projects for another day.

I was able to fit all 10 wheels in my M3 as well as Recaro Profi he gave me just to get it out of his shop. Missing cushions so another side quest of finding those has begun.


Here is a video of 12 year old me riding in that car on those wheels, 12 years ago.

https://vimeo.com/63381733

Vanos and wheels by Kurvenkamph Motorsport, on Flickr
Vanos and wheels by Kurvenkamph Motorsport, on Flickr
Vanos and wheels by Kurvenkamph Motorsport, on Flickr
Vanos and wheels by Kurvenkamph Motorsport, on Flickr
Vanos and wheels by Kurvenkamph Motorsport, on Flickr


It would be a lot nicer if they matched, but for now this will do.

Vanos and wheels by Kurvenkamph Motorsport, on Flickr
Vanos and wheels by Kurvenkamph Motorsport, on Flickr
Vanos and wheels by Kurvenkamph Motorsport, on Flickr
Vanos and wheels by Kurvenkamph Motorsport, on Flickr

Next project will be brakes I want to do the 996 stuff but will just do the CSL/ZCP brakes for now.

Some other random pictures.
Vanos and wheels by Kurvenkamph Motorsport, on Flickr
Vanos and wheels by Kurvenkamph Motorsport, on Flickr
Vanos and wheels by Kurvenkamph Motorsport, on Flickr
Vanos and wheels by Kurvenkamph Motorsport, on FlickrVanos and wheels by Kurvenkamph Motorsport, on Flickr
Vanos and wheels by Kurvenkamph Motorsport, on Flickr

[Loopyspec]

Loving the build and the wrenching you're doing. I wish I was mechanically inclined as you.