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Member Journals Do you have a long term project you would like to share with the community? Use this forum to create a single thread which you can update over time to document the progress.


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Old Sun, Jan-22-2017, 06:09:56 AM   #1
STAATS
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Default 2003 BMW E46 M3 Street / Road Rally Build

Ever since I can remember I have wanted to own an E46 M3... finally in 2014 I had the money and opportunity to make that dream a reality...

I managed to buy a 2003 Titanium Silver model that had been a personal import from the UK to Australia just the year before.

Unfortunately I am really bad at taking photos so the only record I have of it in its original purchased condition are the original CarSales photos (hence you will notice the watermarks).



















Unfortunately after owning it for a while, reinforcing the subframe (Redish plates) and the VANOS (Dr VANOS C300 reinforced hub), I finally found a major breach in the head gasket between Cylinder 1 and Cylinder 2 and major damage to the cylinder wall and head. As a result the engine was basically a write off and left me having to make some major decisions with what I was going to do with the car long term...

Now this car was my dream car... the definition of an all round sports car... older sports cars aren't my style... newer sports cars have more wires then engine... so I decided that I would need to at least look into forging ahead with repairs...

In the background another dream of mine was to one day competing in Targa Tasmania (https://targa.com.au/tc/). So with this in mind I decided to start the undertaking of repairing and upgrading the car in preparation to compete. Now as it stands I still want/need to keep this car as my Daily Driver. As a result of this a lot of the design / upgrade / modification choices will be driven by the need to keep the car street legal and within the Targa Australia regulations.

Throughout this journal I will provide more details of the history and the build as well as links to important information, products or services I have used. Once started I will also post regular revisions to my own personal build journal.

The latest Build Journal can always be found by downloading the latest revision from here: https://drive.google.com/drive/folde...kk?usp=sharing

A comprehensive album of photos from my build can be founder here: https://goo.gl/photos/6Ho6cS8cTmFVpTFL9

So you won't have to go through the whole message board. Although the message board posts will document each stage with added commentary, all of which will end up documented in the above journal and photo album... so it will always be accessible from this first post without having to flick through new posts.
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BMW E46 M3 Vehicle Log Book & Service Tracker Tool: http://www.m3forum.net/m3forum/showthread.php?t=564731

BMW E46 M3 Vehicle Data Record & Modification Journal Template: http://www.m3forum.net/m3forum/showthread.php?t=566440

2003 BMW E46 M3 Street / Road Rally Build: http://www.m3forum.net/m3forum/showthread.php?t=566468

Last edited by STAATS; Tue, Aug-29-2017 at 06:14:02 AM. Reason: Updated Photo Links & Added Link to Build Journal
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Old Sun, Jan-22-2017, 07:44:07 AM   #2
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Default Re: 2003 BMW E46 M3 Street / Road Rally Build

Nice! - looking forward to following your journal
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Old Sun, Jan-22-2017, 11:19:05 AM   #3
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Default Re: 2003 BMW E46 M3 Street / Road Rally Build

Sorry to hear about the engine. You could DIY it and learn a lot
Also, subscribed
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Old Mon, Jan-23-2017, 09:04:51 AM   #4
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Default Vehicle Specifications and Modification List

Okay here is the first set of details... nothing is final yet but below is the indicative vehicle build plan/sheet... I am still very much in the process of deciding on and budgeting for a lot of the below so comments are welcome and everything has potential to change but I am reasonably set on most of it if I can make the budget work.

Vehicle Specifications
BMW E46 M3
Build Date: 01/2003
6MT
Titanium Silver
Black Nappa Leather
Premium Package
Cold weather package
Harmon Kardon
Sunroof

Modification List

Drivetrain
Lang Racing Development Long Block Rebuild
Lang Racing Development Performance Head
Lang Racing Development Crankshaft Journal Bearing Widening
Lang Racing Development EGR cover
ARP head bolts
Dr VANOS Rebuilt VANOS unit and solenoid
Dr VANOS C300 reinforced cryo VANOS exhaust hub
Dr VANOS Exhaust hub bolt kit
Dr VANOS Stage-II rattle reduction kit
Evolve carbon fiber airbox
Evolve custom tune
- Alpha-N
- Shift lights for Manual
- Cold Start delete
- Secondary Air Pump delete
- Speed limiter removed
- *M-track mode
- *Digital Speedometer
- *Cluster Oil Level Indicator
TTFS MAP rail
TTFS DME upgrade
Schrick 280/272 cams
Schrick DLC coated rocker arms
Supersprint Stepped headers
Supersprint Metallic Cats section 1
Supersprint Resonated section 2
Supersprint “Sports” muffler
Moroso Aluminium Coolant Expansion Tank
Mishimoto Performance Aluminum Radiator
Mishimoto Performance Aluminum Fan Shroud Kit
Mishimoto Silicone Radiator Hose Kit
Mishimoto Adjustable Fan Controller Kit
Mishimoto Oil Cooler Kit
Rogue Engineering Performance Engine Mounts
Rogue Engineering coolant overflow line
Rogue Engineering VANOS oil line
Radium Engineering Oil Catch Can Kit
Radium Engineering Fuel Rail Kit
Radium Engineering Fuel Surge Tank
Radium Engineering Fuel Pump Kit
Goodridge G-Link Pull Type Fuel Connector Socket/Plug

Exterior
HARD Motorsport Street Brake duct Cooling Kit
HARD Motorsport Cold Air Intake take-off (y-pipe)
Go Gear Motorsport decals (battery isolation and tow point)

Suspension
KW Clubsport 3-Way Adjustable
KW Suspension front camber plates
ECS Rear upper strut mount
Turner Motorsport Front Sway Bar
Turner Motorsport adjustable front sway bar links
Turner Motorsport Rear Sway Bar
Turner Motorsport adjustable rear sway bar links
ECS Tuning Rear Control Arms
Mason Engineering Front Strut Brace
Mason Engineering Rear Strut Brace
Turner Motorsport Front Subframe Reinforcement kit
Redish Motorsport Rear Subframe Reinforcement kit
VinceBar RACP Reinforcement
Powerflex Street rear subframe bushings
ECS Monoball Rear Shock Mounts
Turner Motosport Monoball Front Control Arm Bushings
Syncro Design Works Monoball Rear Trailing Arm Bushings

Brakes
Brembo GT 6pot 380mm Front BBK
Brembo GT 4pot 345mm Rear BBK

Interior
AGI Precision 4pt bolt-in half cage
SFI-45 Roll Cage Padding
AVIN Avant-2 Head Unit
- Dash camera
- Rear parking camera
- Digital Radio
- 3G
- *Digital Television
- Bluetooth OBD-II connection
- Auxiliary / USB input (dash mounted)
*Fire extinguisher 1kg (driver’s seat mounted)
*Fire extinguisher 1kg (passenger’s seat mounted)
*First-aid Kit (passenger seat mounted)
*Kill switch (dash mounted)
*Battery Isolator (boot panel mounted)
*CTEK Battery Quick Charge Connector (boot panel mount)
*12V Power Socket (boot panel mount)

Wheels
BMW Style 67 19” Wheels
*CSL 19” Wheels
*Michelin Pilot Super Sports


I have also started putting together a Word Doc Build Journal which I will update as I work through the process and document on the message board. It is kept here: https://www.dropbox.com/sh/81zcxjok4...bbupa0EBa?dl=0
I have also added this link to the first post so anyone can link from the first post and download the latest revision of the ongoing Build Journal as I go... in case they don't want to flick the whole way through the message board.
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BMW E46 M3 Vehicle Log Book & Service Tracker Tool: http://www.m3forum.net/m3forum/showthread.php?t=564731

BMW E46 M3 Vehicle Data Record & Modification Journal Template: http://www.m3forum.net/m3forum/showthread.php?t=566440

2003 BMW E46 M3 Street / Road Rally Build: http://www.m3forum.net/m3forum/showthread.php?t=566468

Last edited by STAATS; Sun, Aug-20-2017 at 03:49:07 AM. Reason: Correct Spelling and Links
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Old Mon, Jan-23-2017, 06:34:31 PM   #5
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Default Re: 2003 BMW E46 M3 Street / Road Rally Build

Wow, that's a rather massive and impressive list!
What's your planned build time?


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Old Mon, Jan-23-2017, 09:50:23 PM   #6
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Default Re: 2003 BMW E46 M3 Street / Road Rally Build

I haven't really thought about build time yet. I am currently on rostered work so I work 3weeks in South Korea and then get to go home to Australia for 3weeks. So I have been trying to do most of the organisation / planning / budgeting side of things while I am in Korea and then obviously get down to work when I am back in Australia...

I am still a little on the fence about the entire build due to the overall undertaking and at the moment I am kind of dragging my feet while I wait for feedback from the Department of Transport on my Vehicle Modification Application. Once I get that back I really have no more excuses and I will need to finalise build options with Lang Racing Development and then get the ball rolling.
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BMW E46 M3 Vehicle Log Book & Service Tracker Tool: http://www.m3forum.net/m3forum/showthread.php?t=564731

BMW E46 M3 Vehicle Data Record & Modification Journal Template: http://www.m3forum.net/m3forum/showthread.php?t=566440

2003 BMW E46 M3 Street / Road Rally Build: http://www.m3forum.net/m3forum/showthread.php?t=566468
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Old Wed, Jan-25-2017, 05:24:15 AM   #7
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Default The Engine Damage which started this Project

I managed to track down some photos I took when I have the head off the car and found the engine block damage which has sent me down the path of the rebuild and this overall project.

Unfortunately the photos are really poor and only of the damage to the block, none of the damage to the head.

These are photos of the Cylinder Wall between Cylinder 1 and 2.









I have not been very good at taking and keeping photos up until now so I will also try track down some of the photos of my Redish Plates install. So then I can show everything that has been done up until now before I start the proposed modifications...
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BMW E46 M3 Vehicle Log Book & Service Tracker Tool: http://www.m3forum.net/m3forum/showthread.php?t=564731

BMW E46 M3 Vehicle Data Record & Modification Journal Template: http://www.m3forum.net/m3forum/showthread.php?t=566440

2003 BMW E46 M3 Street / Road Rally Build: http://www.m3forum.net/m3forum/showthread.php?t=566468

Last edited by STAATS; Wed, Mar-29-2017 at 07:10:28 AM. Reason: Amended picture sizes and Spelling mistake
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Old Thu, Jan-26-2017, 04:26:36 AM   #8
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Default Department of Transport "in principle" Approval

So I finally received "in principle" approval from the Department of Transport for my Modification Application. Unfortunately, despite my cover letter stressing the pre-engineered nature of the modifications I proposed, they have requested an Engineering Report to support approval.

I found out one of the approved Engineering Signatories is the guy that actually started the FSAE team which I was on at University for 3years so I have contacted him for advice on the Engineering Approval, Inspection and Sign-off process for vehicle modifications. Luckily over here you only have to do it once to get it approved and there isn't a annual inspection or anything (or though I will be required to do that as part of getting the vehicle a CAMS Log Book but that's another story)...

Anyway for anyone interested in following the story or for those of you in Western Australia who are interested in seeing how the Vehicle Modification process works I have uploaded redacted versions of my original Application and the Approval letter.

This build is now heavily dependant on the feedback I get from the Engineering Signatory so I will provide another update when I hear back from him as his response could very well make or break this build...

Also as a response to a previous query on how long I though the build would take... the deadline for modification based on this approval (according to the letter) is 2years so I guess that at least sets the longest time I can let it drag out for...
Attached Files
File Type: pdf ModificationLightVehicles-BMWE46M3-Redacted.pdf (222.8 KB, 9 views)
File Type: pdf DoTApprovalLetter-BMWE46M3-Redacted.pdf (651.7 KB, 6 views)
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BMW E46 M3 Vehicle Log Book & Service Tracker Tool: http://www.m3forum.net/m3forum/showthread.php?t=564731

BMW E46 M3 Vehicle Data Record & Modification Journal Template: http://www.m3forum.net/m3forum/showthread.php?t=566440

2003 BMW E46 M3 Street / Road Rally Build: http://www.m3forum.net/m3forum/showthread.php?t=566468
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Old Thu, Jan-26-2017, 02:31:22 PM   #9
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Default Re: 2003 BMW E46 M3 Street / Road Rally Build

what feedback are you waiting on? i went through similar process with my last E36 M3 when it received a yellow sticker, and i put in same paperwork as you have, for coilovers, exhaust, braided brake lines and couple of other things and basically what DOT has given you is approval to carry out the modifications. then you take to engineer who goes over it and makes a report to DoT (and charge a hefty amount). then im pretty sure you take the car to DoT again (i did cos i had a yellow sticker still), which goes over report and makes sure all thats included in engineer report is installed (basically making sure you havent done extra mods without seeking approval), and final Mod permit is given
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Old Thu, Jan-26-2017, 03:02:56 PM   #10
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Default Re: 2003 BMW E46 M3 Street / Road Rally Build

That whole modding process sounds terribly complicated ! Good luck getting it done...
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Discussing 2003 BMW E46 M3 Street / Road Rally Build in the Member Journals Forum - Do you have a long term project you would like to share with the community? Use this forum to create a single thread which you can update over time to document the progress. at BMW M3 Forum.com (E30 M3 | E36 M3 | E46 M3 | E92 M3 | F80/X)