E46 M3 tidy up.

[shane@mbtech]

As you guys know, I bought the M3 from Martin.

Whilst it was in ok condition, it was not up to my Standards.

Quick once over revealed a few things I needed to replace.

Slight play in track rod ends and tie rods
Play in all 4 rear control arm hub bushes
Osr caliper sticking
Rear discs required
Rear brake lines heavily corroded
Diff was heavily worn and clunking.
Thread was stripped on osr trailing arm where the shock bolts to
Power steering hose leaking
And a few other little tidy up bits.

I was getting Simpsons to make a rear strut cage section tying into boot floor and plating boot floor, but the fact the brake lines and bushes needed doing meant I decided to tackle these issues first.

The boot floor was crack free upon initial inspection.

I dropped the rear subframe, exhaust, petrol tank, and all suspension. I could then get a better look at the boot floor, to my surprise not one crack starting, not bad for a 51 plate with 60k.

So after dismantling the rear end completely I compiled a small;) list of things that I would replace/fix.

Spherical rtab solid bushes
Solid subframe bushes
High grade polybushes for diff mounting
Oem BMW hub bushes x 4
Various new bolts and nuts
Rear adjustable camber arms
New caliper
New oem rear discs
Pagid Rs 29 rear pads
Hel rear braided hoses
Rear brake lines
Boot floor reinforcing kit
4.10 diff rebuild

KW roll bars front and rear
Alcon front brake kit
Super pro castor front wishbone bushes
Track rod ends and tie rods
Power steering pipe
Carbon airbox
Full service, all oils etc.
Our own designed exhaust system
Rear spoiler from Martin
Front splitter, a combination of carbon lip and APR flat splitter.


Before all of this, when the car was mobile and on the road, I set about designing an exhaust, I carried out lots of research, and came up with a design.

The brief.....

Quiet enough to get on all tracks
No cats
Single exit for weight saving
As unrestrictive as possible for power gain
Sound nice.

Our fabricators work is fantastic so we set about the task. A couple of days work later and we had a prototype. I tested this for a few hundred miles and I was very impressed with the results.

It sounds great, doesn't drone at cruising speeds, butt dyno felt good, it was light too- bonus. 18kg in total for the manifold back system. Stock system is 40kg.

94db @ 5000rpm
98db @ 6000rpm


A few little tweaks were needed and our fab guy set about jigging it up.
Fast forward 2 weeks and we fitted our exhaust to wills car (business partner), together with a Geoff Steele carbon airbox. We then handed the car over to Wayne @ chip wizards to work his magic. He told us with the spec we have that most cars do approx 360bhp after map. So we were extremely pleased and surprised that the car made a very healthy 385bhp. Exhaust works a treat.
I then drove Wills car and it drives superb, and pulls eagerly, certainly the best mapped s54 I've driven. Big thanks to Wayne for the superb Map, it's ultra smooth and so responsive on the road.



To be continued with pics(it's late ) .........

[Brandtner]

Sounds great. Looking forward to pics. I want to do something similar.

[DazBlackCSL]

Nice work Shane look forward to hearing and seeing the updates :thumbs:

[rstoughy]

Excellent write up Shane.
Looking forward to seeing the pics and seeing it out :smokin:

[Mike R]

This thread is useless without pictures :gayfight: :blalalala:.

[CraigMillwardCroft]

We need pictures as most of us cannot read or write :whistle:

[shane@mbtech]

Started out looking similar to this.


10084

[Graham]

I would be dubious of the 385bhp figure but I very much look forwards to pics :thumbs:

[shane@mbtech]

I need to get on photobucket and upload some pics. I'll get some uploaded tonight.

[shane@mbtech]

I would be dubious of the 385bhp figure but I very much look forwards to pics :thumbs:

Me too, but we were told it would do 360 and it did more. We are happy with 360 but it did more. And having driven many many e46 m3 inc many different csl, mapped and standard, it does go extremely well.

I suppose the proof is in the pudding out on track.

[shane@mbtech]

Reserved

[shimmy]

I would be dubious of the 385bhp figure but I very much look forwards to pics :thumbs:

No that sounds very likely.....we can all blame the extra power then when Lawsy shoots by us (and off) at Cascades!

[Graham]

Me too, but we were told it would do 360 and it did more. We are happy with 360 but it did more. And having driven many many e46 m3 inc many different csl, mapped and standard, it does go extremely well.

I suppose the proof is in the pudding out on track.
Only reason I say be dubious is after talking to evolve & Geoff Steel Racing about power figures and both companies said 370bhp without engine work. But it does also depend on many variables on a dyno. It's how it feels on track like you say

[shane@mbtech]

Only reason I say be dubious is after talking to evolve & Geoff Steel Racing about power figures and both companies said 370bhp without engine work. But it does also depend on many variables on a dyno. It's how it feels on track like you say

I'm with you graham, we expected and predicted 355-360, It might be incorrect figure but our graph compared to a 358bhp car on the same rollers and same spec, shows differences throughout the range. Tbh the figure is irrelevant, it's how it drives and it drives superb. Wayne is no bullshitter either. And he's certainly not daft.

Just fitted my airbox last night, I'm nearly finished on the building back end up, just finishing touches then mine is going to Wayne. See how mine does.

[CSL BEAST]

Compared to data Wayne had on same spec cars on the same dyno just our exhaust difference our car made a lot more torque from 2000-5250rpm just to add to a great write up :thumbs:
Get the photos up mate

[shane@mbtech]

So I dropped the subframe on the floor, it was looking a little worse for wear.

http://i772.photobucket.com/albums/yy9/lawsym3/null_zps6b8baba9.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zps6b8baba9.jpg.html)

http://i772.photobucket.com/albums/yy9/lawsym3/null_zps5c685462.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zps5c685462.jpg.html)

Suspension arms looking weathered and tired

http://i772.photobucket.com/albums/yy9/lawsym3/null_zps6b7488ed.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zps6b7488ed.jpg.html)

Whilst the boot floor was crack free, the underneath showed signs of age, 12 yrs of british weather.

http://i772.photobucket.com/albums/yy9/lawsym3/null_zps758a58b7.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zps758a58b7.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zps829ba735.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zps829ba735.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zps9a283c31.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zps9a283c31.jpg.html)

http://i772.photobucket.com/albums/yy9/lawsym3/null_zpse06fbbc0.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zpse06fbbc0.jpg.html)

http://i772.photobucket.com/albums/yy9/lawsym3/null_zpsb8e06c4f.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zpsb8e06c4f.jpg.html)

[shane@mbtech]

I then took the floor back to bare metal for welding the plates in, In know some are sceptical, but its better than doing nothing. http://i772.photobucket.com/albums/yy9/lawsym3/null_zpsa561d800.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zpsa561d800.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zpsbf5870cf.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zpsbf5870cf.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zps419bf0db.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zps419bf0db.jpg.html)
I then rubbed the RTA down and gave them a lick of paint. I also installed the solid bushes at this point.
From this
http://i772.photobucket.com/albums/yy9/lawsym3/null_zps4606a879.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zps4606a879.jpg.html)
to this
http://i772.photobucket.com/albums/yy9/lawsym3/null_zps64628506.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zps64628506.jpg.html)
The diff arrived back from rebuild, I went for 4.10 CWP and plated diff. The bits from blasting and powder coating also landed.

I installed new OEM bushes in the hubs and arms, and solid bushed the subframe.
http://i772.photobucket.com/albums/yy9/lawsym3/null_zps7a98e502.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zps7a98e502.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zpsfe8150b7.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zpsfe8150b7.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zps88f091fd.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zps88f091fd.jpg.html)

[shane@mbtech]

I then thoroughly cleaned the underfloor area and under arches. I then etch primed any bare metal, applied a couple of coats of stone chip and then a few coats of red.
http://i772.photobucket.com/albums/yy9/lawsym3/null_zpsc3a0cc7c.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zpsc3a0cc7c.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zpsf1465a32.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zpsf1465a32.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zpsabb90595.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zpsabb90595.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zps2d5e20b5.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zps2d5e20b5.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zps6d0dad82.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zps6d0dad82.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zps36c882f2.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zps36c882f2.jpg.html)
I also routed my brake lines
http://i772.photobucket.com/albums/yy9/lawsym3/null_zpsedae412c.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zpsedae412c.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zps0e3bf06e.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zps0e3bf06e.jpg.html)
In went the fuel tank after a good clean
http://i772.photobucket.com/albums/yy9/lawsym3/null_zps785f6ccd.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zps785f6ccd.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zps3fa54cc7.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zps3fa54cc7.jpg.html)
I then started to piece together the jigsaw
http://i772.photobucket.com/albums/yy9/lawsym3/null_zps6f031602.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zps6f031602.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zpsd2b6581a.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zpsd2b6581a.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zps284dcbde.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zps284dcbde.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zps256ed096.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zps256ed096.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zpsee6f8cb0.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zpsee6f8cb0.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zpsbff16ece.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zpsbff16ece.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zpsd048f3f4.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zpsd048f3f4.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zpse0f42e8f.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zpse0f42e8f.jpg.html)
I then fitted the rear brakes, renewed the rear calipers. And fitted stud kit.
http://i772.photobucket.com/albums/yy9/lawsym3/null_zpsd61b1521.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zpsd61b1521.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zps7dd17abf.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zps7dd17abf.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zpsac7d6060.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zpsac7d6060.jpg.html)
I fitted the alcons to the front
http://i772.photobucket.com/albums/yy9/lawsym3/null_zps7929e571.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zps7929e571.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zpsc558f60a.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zpsc558f60a.jpg.html)
I then fitted the castor bushes to the front arms, fitted the front roll bar, cleaned up the wishbones, fitted new engine mounts, fitted new PAS pipe. New track rod ends and tie tods.
http://i772.photobucket.com/albums/yy9/lawsym3/null_zps38c4b01c.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zps38c4b01c.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zps283aa5cd.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zps283aa5cd.jpg.html)
http://i772.photobucket.com/albums/yy9/lawsym3/null_zpsb121a883.jpg (http://s772.photobucket.com/user/lawsym3/media/null_zpsb121a883.jpg.html)


I started the airbox install last night. Updates coming next week.
Bumpers are away getting refreshed and exhaust fitting next week.

[CraigMillwardCroft]

The underneath is looking good a good colour scheme :thumbs:

[shane@mbtech]

quick vid of exhaust take off on Wills car.

http://i772.photobucket.com/albums/yy9/lawsym3/th_DE33CEBB-5505-467E-A6C0-A2F5BE80C36E-157-0000000EE55EAE3D_zps5342ddd2.jpg (http://i772.photobucket.com/albums/yy9/lawsym3/DE33CEBB-5505-467E-A6C0-A2F5BE80C36E-157-0000000EE55EAE3D_zps5342ddd2.mp4)

[mattCSLnut]

Good job Shane :thumbs: you planning on injecting the structural foam into the cavity to stop the flexing ?
BTW... is this (pic below) the infamous PAS pipe that's know to fail on the E46 M3s ?

[shane@mbtech]

Good job Shane :thumbs: you planning on injecting the structural foam into the cavity to stop the flexing ?
BTW... is this (pic below) the infamous PAS pipe that's know to fail on the E46 M3s ?

Yes, injecting foam after I get strut brace welded into floor.

And yes that's the very pipe Matt. Prepped 3 m3 for track work recently and they all needed that pipe.

[derek]

Hi Shane are you planning on selling car as I know you never keep a car long. If so give me a shout.

[shimmy]

Hi Shane are you planning on selling car as I know you never keep a car long. If so give me a shout.


Is the earth round? :beer:

[mattCSLnut]

Yes, injecting foam after I get strut brace welded into floor.
That'll be rock solid :thumbs:

And yes that's the very pipe Matt. Prepped 3 m3 for track work recently and they all needed that pipe.

I'd better check mine as it's still the original one.

[CSL BEAST]

Awesome job mate done thoroughly .Don't think he will be selling this one labour of love this has been :smt055

[J2LTB]

Looking good :thumbs:

[AlexGTT]

Cracking job Shane.:thumbs: Always good to sort out the grim under there and good plating.

[Rick H]

From Urban Dictionary:

Plating: A sexual act wherein one partner lies face up on the floor with a plate of glass over their face, and the other ***** on the glass.

[shane@mbtech]

Hi Shane are you planning on selling car as I know you never keep a car long. If so give me a shout.

From Urban Dictionary:

Plating: A sexual act wherein one partner lies face up on the floor with a plate of glass over their face, and the other ***** on the glass.

Much safer to buy a glass coffee table. Whilst some blokes (many on here) have a penchant for big ladies I would advise toughened glass.

[DazBlackCSL]

Much safer to buy a glass coffee table. Whilst some blokes (many on here) have a penchant for big ladies I would advise toughened glass.

Lol :hahaha:

[AlexGTT]

From Urban Dictionary:

Plating: A sexual act wherein one partner lies face up on the floor with a plate of glass over their face, and the other ***** on the glass.

Now you've corrupted my innocent mind!:bigcry:

[Graham]

This is very nice to see I would love to do this to mine one day, great job :thumbs:

[pinkpanther008]

You just happen to have a glass table right?:blalalala:

This is very nice to see I would love to do this to mine one day, great job :thumbs:

[shane@mbtech]

Exhaust on
Custom half my old smashed up CSL diffuser morphed with the standard diffuser.
Airbox fitted


http://i772.photobucket.com/albums/yy9/lawsym3/null_zps49e52127.jpg

http://i772.photobucket.com/albums/yy9/lawsym3/null_zpse37ea75e.jpg

http://i772.photobucket.com/albums/yy9/lawsym3/null_zps5c012c65.jpg

http://i772.photobucket.com/albums/yy9/lawsym3/null_zpsa7513cc7.jpg

http://i772.photobucket.com/albums/yy9/lawsym3/null_zps845bd09a.jpg

http://i772.photobucket.com/albums/yy9/lawsym3/null_zps4069e545.jpg

http://i772.photobucket.com/albums/yy9/lawsym3/null_zpsc05344e4.jpg

[derek]

Looking good Shane. I think I will go for the 316i not as well modded as yours.