[tetsuo111]

The New Year coincides with five months since taking delivery of this car. It seems like an appropriate time to consider progress (or lack thereof) and direction for the upcoming season.

I took delivery of this Black Pearl last August. This car is the Unicorn: E91 6MT RWD ZSP with only 35k miles. I considered keeping her 100% stock. On the other hand, where's the entertainment in that? I enjoyed the last car tremendously, but am aware that some of my passengers were less thrilled. So I decided to limit mods to mostly cosmetic, at least until we had a second vehicle for family duty. Given the handling and driving-centric spirit of my last build, this one was rather mild. Too mild.

On the last car, the order of precedence was: 1) brakes 2) suspension 3) power, and 4) aesthetics. That build order worked well and I wanted to do it again. Sadly, on this car, the build lacked organization and focus, mostly because I prioritized reusing performance parts salvaged from the old car, and I wanted to keep the car "family friendly".

We took delivery of our family daily-duty vehicle recently (new Jeep Grand Cherokee). I already have an AFE Magnum GT CAI and conical air filter for the GC, and suspension upgrades in the queue, but that's another story for a different forum... So the family's happy now, and I (finally) have no reservations about moving forward on this E91.

So what's in the pipeline? My plan is an E91 -> M3 conversion, but with a twist. With inspiration from 63NP, NYBulldog, ilikebmxbikes ), and others, this wagon is getting the M3 treatment, from the inside -> out. There are no plans to install an M3 body kit, rather the focus is on the mechanical and electrical systems that differentiate an M3 from non-Ms. The conversion will probably be limited to chassis, brakes, suspension, and steering, but the conversion will be extensive within this scope. Since I'm beginning with the foundation (chassis upgraded to M3 specs), I retain the option to go all-in with a S65 at some point in the future.

2018 Updated Plan:

Phase 1: Transfer parts salvaged from the old car. Phase 1 is finished

Interior Conversion to M3+
- Recaro Profi
- M3+ interior (steering wheel, instrument cluster, interior trim, ZHP shift knob, GTS Alcantara armrest, AutoSolution SSK, M3 shifter insert)

Chassis
- M3 strut tower brace
- M3 rear chassis brace
- M3 engine cowl and microfilters
- Euro 330i rear bumper bar (10.5 lbs)

Intake
- Cyba scoops
- M Performance N52 intake
- OEM Euro N52 airbox
- Hendrick's 3" carbon fiber CAI
- AFE Pro Dry air filter
- Rev Motorsports silicon TB hose
- OEM 330i 3IM DISA intake manifold

Exterior
- M Performance black grills
- Lux A.E.

Exhaust
- Dundon Motorsports 20 gauge 321 stainless exhaust with Coast Fabrication muffler, Vibrant resonator, Inconel tips, SuperSprint mid-pipes

Phase 2: M-Performance Aerodynamics kit

I love this body kit, installed it on the old car, and was always happy to never see another like it on the road. The panels look like they were sculpted in the wind tunnel because... they are. There are obvious similarities with the body kit used by BMW teams for the WTCC and BTCC series.

When I ordered the kit last November, I learned that it's been discontinued, there are none available for sale in N America, and there are only four remaining on the Continent. Those were the last ones available to buy. I moved mountains to get them. Now I have them, they're painted and I just need time to install.

Phase 3: Chassis

The chassis is the foundation of the car. It needs to be stiff and strong. Performance parts contribute little if the chassis flexes like jello. This is why the M3 has so many chassis stiffeners and reinforcements not found on our non-Ms. I had already installed several M3 chassis braces with the glaring exception of the large front subframe reinforcement and stiffening plate. I have a stiffening plate to play with, and will figure out a way to install.

Phase 4: SuperSprint headers

These are already ceramic coated and just waiting to be installed. I will install a larger muffler on the cat-back system to mitigate noise, first.

Phase 5: The Great Unknown - Suspension, Brakes, and Steering

So if you bothered reading this far, you might wonder why the brakes and suspension are still untouched. Good question! On the last car, everything was upgraded: ST BBK, ss brake lines, TC Kline suspension, camber plates, M3 control arms, PG LSD, low-compliance drivetrain mounts, bushings, etc. The only remaining part of the old suspension was the subframe itself.

For this car it makes sense (to me) to simply install the entire M3 rear subframe and suspension, rather than do the job bit by bit. This plan appeals because I can use an M3 LSD rather than a custom LSD installed in a non-M pumpkin. In the front I'll retain the stock subframe to cradle the I6, and convert everything else: brakes, coilovers, and hubs.

The M3 hubs differ from the non-M. They're stronger, provide better damper support, and have different attachment points for the control arm geometry, for improved handling.

Phase 5: Power

The sole power upgrade in the queue is MILVs, available from CobraMarty. I have my MILVs, and will install after completing the other projects.

The Holy Grail is an S65 swap. This plan retains the option to do a swap in the future, the right way, with a proper chassis, brakes, suspension, and steering setup. If I move forward, it will only be AFTER installing the full control system suite and M3 wiring harness.

It's good having options...