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

[samthejam]

Have you measured your ride height yet as it sits now? Sorry if I missed it.

Alignment spec is -3.5 front (no toe), -2 rear (factory toe)?

Love those SSRs!!

I keep forgetting to check this. I forget exactly what it is but I remember raising the rear because of this thread.

https://nam3forum.com/forums/forum/main-forum/e46-2001-2006/9123-e46-m3-suspension-setup-or-how-to-not-downgrade-your-car-with-suspension-mods

It is somewhere in this window but I am limited in what I can do since my fronts are at max height with this GC setup until I get taller springs but I like the height so probably won't change.

[cornerbalanced]

Have you measured your ride height yet as it sits now? Sorry if I missed it.

Alignment spec is -3.5 front (no toe), -2 rear (factory toe)?

Love those SSRs!!

[jayjaya29]

Big 3 done!

[samthejam]

Thanks George!


Untitled by Kurvenkamph Motorsport, on Flickr
Took Friday off work, after a friend offered he could help weld in the Subframe plates. I had to rent the shop space, but that's okay. Was able to align it there and everything. I also paid my friend for the labor of welding, cutting and grinding basically hot glueing the plates in and repairing any damage. Glad I did came out better than I would've. Picture of on my way there.

Untitled by Kurvenkamph Motorsport, on Flickr


Onto the pictures.
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After an hour or so

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It was time to replace the subframe bushing with AKG 75D as well as replace the cracked right rear spring arm, I had been fully relying on the stainless steel reinforcement to hold it together. Even though I was at a BMW specialist they did not have a tool that was fairly easy to remove the subframe bushings. However I brought my RTAB tool because I thought I read that would work. It didn't, but I fiddlefucked with it and made it work.

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

Worked like an absolute treat with the torch. No impact just a regular 3/8th ratchet. Hammered the new AKGs into their new home.
Untitled by Kurvenkamph Motorsport, on Flickr

Onto the spring arm and guibo. I sourced a brand used one.
Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr

Basically where it stopped for Friday, besides having the area cleaned and inspected. We found 3 areas that were cracked.
Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr



Came back Saturday morning and my friend was feeling a lot better and cranked it out.
Untitled by Kurvenkamph Motorsport, on Flickr

Welded up the cracks, and note the gas tank is still in there. Those got covered with wet towels when welded. The Reddish plates were huge so we trimmed them a bit, as I did not want to mess with dropping the tank. I did show up with it with less than a gallon, but we worked around it.

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

I also found a Hotchkis swaybar laying around the shop, so put that on. Was very pleased about that.
Untitled by Kurvenkamph Motorsport, on Flickr

I haven't been able to do my alignment myself on a machine in a long time, so that was a fucking treat.
Untitled by Kurvenkamph Motorsport, on Flickr

Forgot to take a pic but -3.5 camber in front, zero toe, didn't hit my camber number I wanted on RR for some reason. So it was -2.0 and -1.6, rear toe is just factory specs.

Car drives great, absolutely transformed can feel what the rear end is doing now and the front bar really helped with the softer spring rate I have up there.

Untitled by Kurvenkamph Motorsport, on Flickr

Untitled by Kurvenkamph Motorsport, on Flickr

Total time spent doing everything was 24 hours, two 12 hour days.

[George Hill]

congrats on the wedding!

[samthejam]

Ordered the Reddish subframe reinforcement and AKG 75D subframe bushings, so that is next. My suspicions of the car having a tune have been confirmed, cat deficiency always showed as not ready. No CEL yet after the headers. When we did the CSL shift setting and 105 DTC error disabled. We used Martyn's tool and Cat deficiency was greyed out. I saw this before on a friends car but it was for the burble setting, so someone has tampered with it and software won't let you touch that setting. So no idea what's on it but someone has cooked here before.

CPV valve is starting to leak but didn't have the tool or the part so that is ordered as well.

[samthejam]

As promised, only did the front rotors for now. Rear rotors still good so want to get moneys worth out of those.

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

Also sourced all the missing OE stuff for the battery. Little things.
Untitled by Kurvenkamph Motorsport, on Flickr

I daily drive with the PFC 08s so the brake dust is horrednous.
Untitled by Kurvenkamph Motorsport, on Flickr


Had a wedding
Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr

Instead of honeymoon, decided to do headers. That was a debacle.
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 did trans mounts
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Untitled by Kurvenkamph Motorsport, on Flickr

Has a really interesting exhaust note, definitely doesn't sound like the BW exhaust I have mostly heard.
Megans, stock section 1 and their street track section to the back.

https://youtube.com/shorts/YnXjFI84Etk?si=6l7yJPmnC2eBBgKs

https://youtube.com/shorts/CcqBaVtJbOI?si=8yK9JPV52NNel1r2

[Loopyspec]

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

[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

[samthejam]

Turn signal has some RS4 on it now.

September Update by Kurvenkamph Motorsport, on Flickr

[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]

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]

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]

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

[Sharocks]

So I was correct lmao.