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      10-16-2016, 06:23 PM   #23
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Nov 2015

- BMW Performance Aero body kit arrives

The first PA parts delivery was for PDC. Had to return and exchange for the correct non-PDC parts. ECS was quick to respond and take care of the problem.

At least early-winter was bountiful. There was a ton of snow. xDrive and Blizzaks did their thing. Sadly, there were several early season casualties in the deep snow. Sometimes the weather is pleasant, though.
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2011 6MT RWD ClubSport Wagon | 3,185lbs | 1 of 149 ZSPs delivered in North America
Outside: BMW M-Aero, Euro region lighting, Seibon | Inside: M3 cockpit, Recaro SPG, Prototipo, AutoSolutions SSK, UCP | Stop: M3 ST-40R, PFC | Grip: Solid-mounted subframes, rear coilover conversion, M3 Nitron R3, Hyperco, SPL, AKG, ARC8 | Go: StageFP, CF snorkel, 3IM, MILVs, SuperSprint headers, Dundon Motorsports Inconel exhaust, VoltPhreaks | Cool: CSF | PCA #2018100384 | BMW CCA #505794

Last edited by tetsuo111; 10-17-2016 at 04:57 PM..
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      10-16-2016, 06:26 PM   #24
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Read every word, keep the progress and adventure posts coming. Wish I could do the same to my daily driver.
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      10-16-2016, 06:56 PM   #25
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FormulaOne Pinnacle Ceramic Tint

Dec 2015

- Installed 30% ceramic window tint. It's my first car to be tinted. Didn't think that it was my style. Now that it's on, I'm a fan. Installed at Accutint, Seattle. Strongly recommended for appearance work. Accutint details for BMW Seattle. There's always auto exotica in the garage.
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2011 6MT RWD ClubSport Wagon | 3,185lbs | 1 of 149 ZSPs delivered in North America
Outside: BMW M-Aero, Euro region lighting, Seibon | Inside: M3 cockpit, Recaro SPG, Prototipo, AutoSolutions SSK, UCP | Stop: M3 ST-40R, PFC | Grip: Solid-mounted subframes, rear coilover conversion, M3 Nitron R3, Hyperco, SPL, AKG, ARC8 | Go: StageFP, CF snorkel, 3IM, MILVs, SuperSprint headers, Dundon Motorsports Inconel exhaust, VoltPhreaks | Cool: CSF | PCA #2018100384 | BMW CCA #505794
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      10-16-2016, 07:07 PM   #26
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Performance Aero Kit Prep + Spark Plugs

Jan 2016

More Performance Aero parts arriving from ECS. They need to be delivered for painting, so I load them in the cargo area and take them to Metro Auto (recommended). I also reconfigured the CAI snorkel for fitment with the new Performance Aero front bumper cover, and opened the rocker vents for function.

I realize that after a year of ownership, I used this car as a daily driver, an AWD winter mountain ski / climb truck, a track toy, and a cargo hauler. My initial disappointment in the car's performance is being replaced with admiration and respect for its broad capabilities.

I also changed the plugs as preventative maintenance. The old plugs looked fine.
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2011 6MT RWD ClubSport Wagon | 3,185lbs | 1 of 149 ZSPs delivered in North America
Outside: BMW M-Aero, Euro region lighting, Seibon | Inside: M3 cockpit, Recaro SPG, Prototipo, AutoSolutions SSK, UCP | Stop: M3 ST-40R, PFC | Grip: Solid-mounted subframes, rear coilover conversion, M3 Nitron R3, Hyperco, SPL, AKG, ARC8 | Go: StageFP, CF snorkel, 3IM, MILVs, SuperSprint headers, Dundon Motorsports Inconel exhaust, VoltPhreaks | Cool: CSF | PCA #2018100384 | BMW CCA #505794

Last edited by tetsuo111; 10-16-2016 at 07:23 PM..
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      10-16-2016, 07:33 PM   #27
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Fail

Feb 2016

I studied fluid and gas dynamics, but ended up working in a different field. I wanted to vent the rear bumper cover for a discrete functional diffuser by replacing the gray plastic trim with metal mesh. The compound curves were beyond my patience. The result was scratches on my newly painted bumper cover. Bleh.
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2011 6MT RWD ClubSport Wagon | 3,185lbs | 1 of 149 ZSPs delivered in North America
Outside: BMW M-Aero, Euro region lighting, Seibon | Inside: M3 cockpit, Recaro SPG, Prototipo, AutoSolutions SSK, UCP | Stop: M3 ST-40R, PFC | Grip: Solid-mounted subframes, rear coilover conversion, M3 Nitron R3, Hyperco, SPL, AKG, ARC8 | Go: StageFP, CF snorkel, 3IM, MILVs, SuperSprint headers, Dundon Motorsports Inconel exhaust, VoltPhreaks | Cool: CSF | PCA #2018100384 | BMW CCA #505794
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      10-16-2016, 07:43 PM   #28
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Performance Aero Kit Installed

It took months to obtain and prep the panels, but I love the results. I tossed the old bumper front and rear bumper covers. I could have saved them for some future use but I didn't want to keep them in storage, like a ball and chain.
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2011 6MT RWD ClubSport Wagon | 3,185lbs | 1 of 149 ZSPs delivered in North America
Outside: BMW M-Aero, Euro region lighting, Seibon | Inside: M3 cockpit, Recaro SPG, Prototipo, AutoSolutions SSK, UCP | Stop: M3 ST-40R, PFC | Grip: Solid-mounted subframes, rear coilover conversion, M3 Nitron R3, Hyperco, SPL, AKG, ARC8 | Go: StageFP, CF snorkel, 3IM, MILVs, SuperSprint headers, Dundon Motorsports Inconel exhaust, VoltPhreaks | Cool: CSF | PCA #2018100384 | BMW CCA #505794
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      10-16-2016, 08:19 PM   #29
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LSD #1

Feb 2016

Since I started tracking the car, I knew that an LSD was in my future. The motivation was slow, tight turns at Pacific (T3A and 3B) and The Ridge (the thumb and corkscrew). The stock open differential is completely fine on the street, but it's weakness is just as clear on the track. I ordered a clutch style 3.91 LSD from Performance Gearing. Specs: 4 x 90 mm clutch plates, 80 lbs/ft pre-load, and 30/60 degree ramps on decel and acceleration. PG explained the LSD would be based on a new, updated design.

Install was done by Charles at the same time as the new exhaust. When I picked the car up, Charles said the unit sounded off, like nothing else he heard. When I drove home, the sound was like a giant Cuisinart processor. The sound of sharp metal scraping was obvious. I had three shops audit the unit and installation. The install was fine. The unit was ultimately replaced under warranty.
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2011 6MT RWD ClubSport Wagon | 3,185lbs | 1 of 149 ZSPs delivered in North America
Outside: BMW M-Aero, Euro region lighting, Seibon | Inside: M3 cockpit, Recaro SPG, Prototipo, AutoSolutions SSK, UCP | Stop: M3 ST-40R, PFC | Grip: Solid-mounted subframes, rear coilover conversion, M3 Nitron R3, Hyperco, SPL, AKG, ARC8 | Go: StageFP, CF snorkel, 3IM, MILVs, SuperSprint headers, Dundon Motorsports Inconel exhaust, VoltPhreaks | Cool: CSF | PCA #2018100384 | BMW CCA #505794
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      10-17-2016, 02:30 PM   #30
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Quote:
Originally Posted by tetsuo111 View Post
Feb 2016

I studied fluid and gas dynamics, but ended up working in a different field. I wanted to vent the rear bumper cover for a discrete functional diffuser by replacing the gray plastic trim with metal mesh. The compound curves were beyond my patience. The result was scratches on my newly painted bumper cover. Bleh.
Ha, working on my thermal fluid science master's right now. I typically don't even bother with application to my car, others can do that work for me.
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      10-17-2016, 04:47 PM   #31
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Originally Posted by Shrike360 View Post
Ha, working on my thermal fluid science master's right now. I typically don't even bother with application to my car, others can do that work for me.
Lol - this car is my rolling science experiment. I'm playing around with stuff must motorheads do, I just waited longer than most in life to get around to it.
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2011 6MT RWD ClubSport Wagon | 3,185lbs | 1 of 149 ZSPs delivered in North America
Outside: BMW M-Aero, Euro region lighting, Seibon | Inside: M3 cockpit, Recaro SPG, Prototipo, AutoSolutions SSK, UCP | Stop: M3 ST-40R, PFC | Grip: Solid-mounted subframes, rear coilover conversion, M3 Nitron R3, Hyperco, SPL, AKG, ARC8 | Go: StageFP, CF snorkel, 3IM, MILVs, SuperSprint headers, Dundon Motorsports Inconel exhaust, VoltPhreaks | Cool: CSF | PCA #2018100384 | BMW CCA #505794
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      10-17-2016, 05:58 PM   #32
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Dundon Motorsports Exhaust

Mar 2016

I met Charles Dundon in Seattle when I was looking for support for the headers. He specializes in Porsche GT3 race cars, but we hit it off and he found the idea of building an exhaust for my wagon entertaining. He designed a GT3 exhaust that seems to be one of the best out there, applying real gas dynamics and engineering together with exotic materials then fabs it himself. The system weighs ~27 lbs and makes 25 whp over the stock GT3 system. And it sounds like Satan.

Here's a 9 page thread on Rennlist devoted to his exhaust:

Custom-built 996 GT3 exhaust 321 stainless

And here's a E90post I made about the project and results:

E91 N52 Exhaust - GT3 Style


That thread turned into a shit show, but if you can stomach through, it documents the build with pictures and videos.

My goal for this project was simply to drop significant weight, while testing ideas on scavenging for power. Sound was irrelevant for me, other than not wanting to be "that guy" in the neighborhood with the obnoxious pipes.

There was a dyno scheduled immediately after installation, but it was cancelled pending resolution of a drivetrain issue that would affect the data. Bottom line - no power or TQ data. The system is around 40 lbs less than stock. The sound is orgasmic over 4k, and borderline under.

Specs: 3" 321 20 gauge stainless, Vibrant 1142 resonator, Coast Fabrication custom 14" suppressor, Dundon venturi Y-merge, Dundon Inconel tips.

After living with this on the car for 6 - 7 months, I'm satisfied. The project was a significant part of the car's weight-loss diet and sounds great. Don't know if I'm adjusting to the exhaust or vice versa, but it seems that the sound has mellowed. The pops and burbles on decel are more than on the PE, and it sounds better than I've heard on an I6 > 4k. Below that it just sounds raw and aggressive. Not quiet, but not as raw as when it was new. The technicians love it. I will return to the dyno soon to wrap everything up with some numbers.



Here's one of a Dundon GT3 exhaust. Skip to 3:15 if you can't watch it all, but keep an eye on the volume.

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2011 6MT RWD ClubSport Wagon | 3,185lbs | 1 of 149 ZSPs delivered in North America
Outside: BMW M-Aero, Euro region lighting, Seibon | Inside: M3 cockpit, Recaro SPG, Prototipo, AutoSolutions SSK, UCP | Stop: M3 ST-40R, PFC | Grip: Solid-mounted subframes, rear coilover conversion, M3 Nitron R3, Hyperco, SPL, AKG, ARC8 | Go: StageFP, CF snorkel, 3IM, MILVs, SuperSprint headers, Dundon Motorsports Inconel exhaust, VoltPhreaks | Cool: CSF | PCA #2018100384 | BMW CCA #505794

Last edited by tetsuo111; 10-17-2016 at 06:28 PM..
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      10-17-2016, 08:08 PM   #33
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Exhaust is amazing. Very nice and purposeful build thus far! Ever planning a 6MT swap?
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      10-18-2016, 07:57 PM   #34
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Quote:
Originally Posted by BrandJas18 View Post
Exhaust is amazing. Very nice and purposeful build thus far! Ever planning a 6MT swap?
Thanks. Sure, I've thought seriously about a 6MT because it would tie everything together so nicely. Still working on some basics, but maybe someday...

I did look for several months during purchase but finally surrendered to the ubiquitous 6AT.
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2011 6MT RWD ClubSport Wagon | 3,185lbs | 1 of 149 ZSPs delivered in North America
Outside: BMW M-Aero, Euro region lighting, Seibon | Inside: M3 cockpit, Recaro SPG, Prototipo, AutoSolutions SSK, UCP | Stop: M3 ST-40R, PFC | Grip: Solid-mounted subframes, rear coilover conversion, M3 Nitron R3, Hyperco, SPL, AKG, ARC8 | Go: StageFP, CF snorkel, 3IM, MILVs, SuperSprint headers, Dundon Motorsports Inconel exhaust, VoltPhreaks | Cool: CSF | PCA #2018100384 | BMW CCA #505794
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      10-18-2016, 08:04 PM   #35
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April 2016

Installed Recaro Profi seats to drop ~ 60 lbs and because I was tired of using my knee against the door to hold myself in place.

Bonus - the Recaros are more comfortable than OEM. Sadly, entrance and egress are challenging. Happily, passengers aren't annoyed, they just laugh at the ridiculousness of the whole thing.
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2011 6MT RWD ClubSport Wagon | 3,185lbs | 1 of 149 ZSPs delivered in North America
Outside: BMW M-Aero, Euro region lighting, Seibon | Inside: M3 cockpit, Recaro SPG, Prototipo, AutoSolutions SSK, UCP | Stop: M3 ST-40R, PFC | Grip: Solid-mounted subframes, rear coilover conversion, M3 Nitron R3, Hyperco, SPL, AKG, ARC8 | Go: StageFP, CF snorkel, 3IM, MILVs, SuperSprint headers, Dundon Motorsports Inconel exhaust, VoltPhreaks | Cool: CSF | PCA #2018100384 | BMW CCA #505794
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      10-18-2016, 09:37 PM   #36
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Quote:
Originally Posted by tetsuo111 View Post
I was tired of using my knee against the door to hold myself in place.
I know that feeling. I'm still looking for an affordable set of recaros for this reason. My door leather is all worn off from my knee.

Also, you should save weight by selling that carbon leather trim to me. You don't need it.
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      10-19-2016, 02:51 PM   #37
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May 2016

- Installed CF fins from forum members Vvroom and Ruddigger
- Installed replacement Performance Gearing 3.91 LSD
- M3 Carbon Kevlar front bumper bar delivered

Pic 1 - Forum members Ruddigger and Vvvroom generously shared a set of CF canards with me from their local group project. I added these to the car just because... It was a pleasure getting to know both Ryan and Moses.

I had the LSD R&R'd. The lubricant from the first unit was shimmery metallic black in color and shows an extraordinary amount of metal bits.
Pic 2 - replacement, new LSD
Pic 3 - original LSD after R&R
Pic 4 - Diff fluid after a few hundred miles

After playing with the car for a year, I'm learning that the most rewarding mods for me are: 1) removing compliance in the suspension and drivetrain, 2) removing weight wherever possible, and 3) N52 power options are very limited.

Pic 5 - I found that the Euro spec and M3 bumper bars are around half the weight of our N American versions. I ordered a M3 front bar and Euro-spec rear bar. Replacing the N American parts with these drops around 22 lbs from the ends of the chassis. I'm convinced that the cumulative result of numerous small weight drops are real and impactful even in daily driving. Less weight puts less load on the suspension, allowing it to work more effectively at controlling weight transfer. The car feels more taught, tight, lithe, agile, nimble, and athletic. All good. Removing weight enhances the stiffness to mass ratio, resulting in better precision and control.

The car is around 300 lbs less than when I took delivery, without impacting daily driveability.
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2011 6MT RWD ClubSport Wagon | 3,185lbs | 1 of 149 ZSPs delivered in North America
Outside: BMW M-Aero, Euro region lighting, Seibon | Inside: M3 cockpit, Recaro SPG, Prototipo, AutoSolutions SSK, UCP | Stop: M3 ST-40R, PFC | Grip: Solid-mounted subframes, rear coilover conversion, M3 Nitron R3, Hyperco, SPL, AKG, ARC8 | Go: StageFP, CF snorkel, 3IM, MILVs, SuperSprint headers, Dundon Motorsports Inconel exhaust, VoltPhreaks | Cool: CSF | PCA #2018100384 | BMW CCA #505794
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      10-20-2016, 04:53 PM   #38
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Jun 2016

- LSD V.2 flush and fill. First flush happened @ first 500 miles, second @ next 700 miles. This is double the interval recommended by the vendor, but clean and fresh lubricant is worth the peace of mind for me now.

- Installed UUC 25.5 mm solid front sway bar and poly bushings. The OEM sway bar is hollow, 26.5 mm diameter at the outer part and 22.5 mm diameter in the center. The E90 M3 sway bar is hollow and 26.5 mm. I have the matching UUC solid adjustable 19.5 mm rear sway bar (compared with OE hollow 13 mm and M3 hollow 22.5 mm rear bar). Maybe another time.
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2011 6MT RWD ClubSport Wagon | 3,185lbs | 1 of 149 ZSPs delivered in North America
Outside: BMW M-Aero, Euro region lighting, Seibon | Inside: M3 cockpit, Recaro SPG, Prototipo, AutoSolutions SSK, UCP | Stop: M3 ST-40R, PFC | Grip: Solid-mounted subframes, rear coilover conversion, M3 Nitron R3, Hyperco, SPL, AKG, ARC8 | Go: StageFP, CF snorkel, 3IM, MILVs, SuperSprint headers, Dundon Motorsports Inconel exhaust, VoltPhreaks | Cool: CSF | PCA #2018100384 | BMW CCA #505794
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      10-20-2016, 07:42 PM   #39
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Jul 2016

- Installed M3 front bumper bar to drop 10 lbs
- Installed Euro 330i rear bumper bar to drop 12 lbs
- Installed Halon extinguisher for safety

More weight loss goodness. While 22 lbs out of 2.5 tons doesn't appear to amount to much, I'm of the opinion that it does. The cumulative impact of many small weight loss projects considered in total is significant. Weight detracts from agility. Period. The wagon is almost 300 lbs less mass than delivered. Meanwhile, the visceral driving experience is transformed for the better - sounds, feedback, agility. I love driving the car now. It feels properly German.

Write-up:
M3 Bumper Bar on Non-M. Don't Do This. UPDATE - Success
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2011 6MT RWD ClubSport Wagon | 3,185lbs | 1 of 149 ZSPs delivered in North America
Outside: BMW M-Aero, Euro region lighting, Seibon | Inside: M3 cockpit, Recaro SPG, Prototipo, AutoSolutions SSK, UCP | Stop: M3 ST-40R, PFC | Grip: Solid-mounted subframes, rear coilover conversion, M3 Nitron R3, Hyperco, SPL, AKG, ARC8 | Go: StageFP, CF snorkel, 3IM, MILVs, SuperSprint headers, Dundon Motorsports Inconel exhaust, VoltPhreaks | Cool: CSF | PCA #2018100384 | BMW CCA #505794

Last edited by tetsuo111; 11-18-2016 at 05:23 AM..
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      10-21-2016, 11:02 AM   #40
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Quote:
Originally Posted by tetsuo111 View Post
The E90 M3 sway bar is hollow and 26.5 mm. and M3 hollow 22.5 mm rear bar.
I thought the m3 bar was 28mm and the rear 23.6?

https://www.ecstuning.com/Search/Sit...Bar/ES2618428/

https://www.ecstuning.com/Search/Sit...Bar/ES2622885/
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      10-21-2016, 08:49 PM   #41
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Originally Posted by Dan Bilzerian View Post
M3 bars come in many flavors, depending on chassis. For instance, the E93 bars are larger than those in the sedan. The coupe E92 may differ, too. I just double checked the front 26.5 mm number on RealOEM and it does match the bar in the sedan.

Some people choose to install the E93 bar because it's stiffer than the E90 bar. I used the order of priority beginning with dampers and springs, then RSBs, camber plates, and front thrust arm bushings. Then a bunch of other suspension upgrades to mitigate compliance. In my case, the sway bar was left until the end, to be used as fine tuning.

The front bar works in my case. Turn-in is sharper and there's less body roll (duh...). I have the rear bar, but haven't yet felt the need to install because the handling feels neutral now.
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2011 6MT RWD ClubSport Wagon | 3,185lbs | 1 of 149 ZSPs delivered in North America
Outside: BMW M-Aero, Euro region lighting, Seibon | Inside: M3 cockpit, Recaro SPG, Prototipo, AutoSolutions SSK, UCP | Stop: M3 ST-40R, PFC | Grip: Solid-mounted subframes, rear coilover conversion, M3 Nitron R3, Hyperco, SPL, AKG, ARC8 | Go: StageFP, CF snorkel, 3IM, MILVs, SuperSprint headers, Dundon Motorsports Inconel exhaust, VoltPhreaks | Cool: CSF | PCA #2018100384 | BMW CCA #505794
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      10-21-2016, 08:53 PM   #42
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Let me know when you make a carbon fiber rear hatch. Lol
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      11-14-2016, 06:37 PM   #43
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I think the sunroof in the front and and the glass roof panel in the rear could be stripped out and replaced with carbon fiber, plexiglass, or fiberglass for substantial weight savings in the roof area. I have doubts that anyone makes those panels. Another solution is just have a body shop remove everything and make custom roof panels of steel to close it off, even if they have to weld it in.
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      11-15-2016, 04:27 AM   #44
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Quote:
Originally Posted by tetsuo111 View Post
Nov 2015

- BMW Performance Aero body kit arrives

The first PA parts delivery was for PDC. Had to return and exchange for the correct non-PDC parts. ECS was quick to respond and take care of the problem.

At least early-winter was bountiful. There was a ton of snow. xDrive and Blizzaks did their thing. Sadly, there were several early season casualties in the deep snow. Sometimes the weather is pleasant, though.
Great build so far! Love your e91. BTW where was the first photo taken at? In Leavenworth?
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