preperation for the TS3 begins

[330i ZHP]

I am going back to a 3.07 LSD (putting the 3.46 LSD in the wagon - for future SC mods)...and performing all the rear suspension re-inforcements including the welding of the rear subframe reinforcements.

Here are the reinforcement parts and below are pics of the swap beginning.... I also bought the following items:

http://www.turnermotorsport.com/image/suspension/susp_e36_rtal.lg.jpg
http://www.turnermotorsport.com/image/suspension/susp_e36_rtal_installed.jpg

TMS Trailing Arm Bushing Limiter Kit
Part #: TSU9990001
Applications: 1992 - 2005 (E36 E46)
The rear trailing-arm bushing limiter kit creates a stiffer suspension without sacrificing ride quality. These kit is a perfect upgrade from stock without the harshness of "race-only" bushings. By combining these limiters with stock bushings, this is a great low cost and effective suspension performance enhancer. By limiting the amount of side-to-side movement of the stock bushing , drivers will have increased driver feel because of the reduction of toe variation due to the squirm of the stock rubber bushings. The bushings will also have longer life. This is also an advantage because many BMW’s have issues with the stock bushings ripping and tearing over time. Some stock class racing series even allow this kind of modification, because the stock bushing is still being used. Kit includes: 4-Blue anodized aluminum bushing limiters, eight 5mm allen bolts and a drilling template.


http://www.turnermotorsport.com/image/suspension/suspension_rear_streinf_lg.jpg
http://www.turnermotorsport.com/image/suspension/suspension_rear_streinf_2_lg.jpg
Rear Shock Tower Mount Reinforcement Kit
Part #: TSU9975100
Applications: 1992 - 2006 (E36 E46)
A common weak point on the 3 series BMW is the rear shock tower. This kit mounts on top of the rear shock tower and can either be bolted or welded in place. These plates are thicker than the factory reinforcement plates.


http://www.turnermotorsport.com/image/suspension/suspension_r_stm_lg.jpg
E30, E36, E46 Aluminum Rear Shock Tower Mounts (pair)
Part #: JTD909
Applications: 1984 - 2005 (E30 E36 E46 Z3)
These are the best rear shock mounts that we have found for the E30, E36, and E46! Featuring CNC-machined billet aluminum mounting base with a replaceable urethane bushing (replacement bushings are just $15 and are changed in minutes!). These mounts are excellent for either street or track because of their low NVH (noise, vibration, and harshness). Plus, the superior design will far outlast the life of stock mounts - maybe even the car itself. You'll never think twice about your shock mounts again! These shock mounts are a direct replacement of the stock mounts so they fit all shocks with the BMW-standard 10mm shock shaft, including all H&R coil overs, Bilstein shocks and PSS, PSS9, PSS10 coil overs (except the B16 Ride Control Kit) and all factory and OEM shocks (Boge, Sachs, etc). This is sold as a package with new shock mount gaskets, washers, and Nyloc nuts.


http://www.turnermotorsport.com/image/suspension/reinf_e46_subframe_lg.jpg
http://www.turnermotorsport.com/image/suspension/reinf_e46_subframe_2.jpg
E46 Rear Chassis Reinforcement Kit
Part #: TDR4675412
Applications: 1999 - 2005 (E46)
The E46 rear driveline and suspension are very similar to that of the E36. An unfortunate side effect of this is that the E46 also shares some of the same problems as the E36. One of these problems is the rear mounting points for the subframe, which can rip out from their spots in the sheet metal. This happens because the rear differential transmits the torsional load from the engine through the subframe, then into the chassis. This constant loading and unloading weakens the sheet metal and causes it to fatigue and separate from the chassis. BMW tried to fix this problem in the E46 by placing a cross member on the front two mounting points of the subframe. This cross member keeps the front mounting points from having problems by placing the bushing and the stud in double-sheer, thus reducing the twisting action on the sheet metal. The unfortunate side effect of this is that the load from the front of the subframe now gets transmitted to the left rear of the subframe. This is where we have seen many failures of the chassis on low mileage street cars and race cars.


E46 Rear Subframe Failure Gallery
The E46 rear driveline and suspension are very similar to that of the E36. An unfortunate side effect of this is that the E46 also shares some of the same problems as the E36. One of these problems is the rear mounting points for the subframe, which can rip out from their spots in the sheet metal. This happens because the rear differential transmits the torsional load from the engine through the subframe, then into the chassis. This constant loading and unloading weakens the sheet metal and causes it to fatigue and separate from the chassis. BMW tried to fix this problem in the E46 by placing a cross member on the front two mounting points of the subframe. This cross member keeps the front mounting points from having problems by placing the bushing and the stud in double-sheer, thus reducing the twisting action on the sheet metal. The unfortunate side effect of this is that the load from the front of the subframe now gets transmitted to the left rear of the subframe. This is where we have seen many failures of the chassis on low mileage street cars and race cars. This product reinforces the chassis sheet metal at the subframe mounting points. We do this by thickening the metal and distributing the load over a larger area. This kit will save time when repairing the chassis, and is also strongly recommended as a preventative maintenance item. Click here for more information on this kit. Below are photos of subframe damage we have repaired in house.

http://www.turnermotorsport.com/image/gallery/e46sf/gallery_e46sf_011306.jpg
http://www.turnermotorsport.com/image/gallery/e46sf/gallery_e46sf_011306_2.jpg
http://www.turnermotorsport.com/image/gallery/e46sf/gallery_e46M3sf_010906.jpg

******* id="VideoPlayback" style="width:400px;height:326px" flashvars="" src="http://video.google.com/googleplayer.swf?docid=8362789948066992482&hl=en" type="application/x-shockwave-flash"> </embed>

Video of what torn subframe mounts look like in action (http://video.google.com/videoplay?docid=8362789948066992482&hl=en)




Here are pics so far - I dont have any with the complete rear out of the car:

http://i225.photobucket.com/albums/dd62/smoulton0204/DSC02906.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/DSC02907.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/DSC02908.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/DSC02917.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/DSC02909.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/DSC02910.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/DSC02911.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/DSC02912.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/DSC02913.jpg

[330i ZHP]

http://i225.photobucket.com/albums/dd62/smoulton0204/DSC02915.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/DSC02916.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/DSC02918.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/DSC02919.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/DSC02920.jpg


Here is some shots of the stage three parts:

http://i225.photobucket.com/albums/dd62/smoulton0204/DSC02921.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/DSC02922.jpg

[330i ZHP]

dear lord the underside of my car is DIRTY!!!!

[330i ZHP]

I was happy to see I could turn the adjusters for the coil-overs with now problem, I guess never driving the car in salt and dirt have helped - I will finally be able to lower the rear ....been lazy

[03SilverE46Conv]

Thats sick dude, its great that you do all the work on your car, i wish i could :rofl:

[2003330i]

stu, you look to be very handy. your car is very nice. i just did the re inforcement kit and rogue rtab's 2 weeks ago. i felt a huge difference. i can only imagine how your car is going to feel after your done

[Nismode]

Looking very nice...CF diffusor looks nice on sapphire black (I think that's your color). Also, what exhaust is that?

And are those DEPO or OEM clears?

OT, I know.

Also, I thought that your ZHP already had FI...

[330i ZHP]

stu, you look to be very handy. your car is very nice. i just did the re inforcement kit and rogue rtab's 2 weeks ago. i felt a huge difference. i can only imagine how your car is going to feel after your done

My car only has 24k miles - so it hasnt felt loose yet.

Looking very nice...CF diffusor looks nice on sapphire black (I think that's your color). Also, what exhaust is that?

And are those DEPO or OEM clears?

OT, I know.

Also, I thought that your ZHP already had FI...

The wagon is Sapphire Black - the sedan is solid black

Those are OEM clears and they are tinted with 4parts clear and 2 parts black...mixed

And yes, the car is stage 2+ but getting ready to go stage 3 (420+hp AT THE WHEELS...so I want to hopefully keep from having any torn or stressed body parts)

[2003330i]

oh okay. yeah i just did it at 80k miles and but this was after i did the kw2's and i felt a bigger difference from the rtab's that i did with the suspension.
i sent you a pm asking you a question. i need some help on something

[ken330i]

oh wow!!! now, i want to be in your garage :drool:

[Lay2Low]

Nice! Good luck and have fun, can't wait to see it completed! What is the ETA?

[kevinterkelsen]

Hi 330iZHP - your project looks EXCELLENT! it looks like you are going all the way and maximizing the value of the TS 3 - your car is going to be a beast!!

In my experience you cannot underestimate how much the power shows of the weaknesses of the e46 - when handling +450 CHP - I simply cannot think of anything that you have not - good luck with the project!

[sillieidiot]

can't wait to see it finished :excited:

[330i ZHP]

Nice! Good luck and have fun, can't wait to see it completed! What is the ETA?

I will be lucky to get the parts in time to complete the rear portion before my wedding in June....then NO WORK will take place in June...and I am hoping to start pulling the motor and trans around July 1st

[330i ZHP]

I need to order a complete set of external torx bolts for the diff - mine are getting pretty chewed up being taken off and installed a few times now.

[aggieE46]

I'm jealous. I love this stuff.

[sheefo2k]

wow goodluck bro!!!
I cant wait to see this beast!!!
put lsd while your at it!! i put mine a week ago and i love it

[330i ZHP]

I have had LSD for two years - I agree, it is one of the best mods.

I am taking the 3.46 LSD from the sedan, swapping the flanges and installing it in the wagon...and the new 3.07 LSD will go in the sedan.

[sheefo2k]

3.07 lsd would be perfect but since you have 6 sp, just stay with the 3.46

[ssm1991]

Your next tool should be a lift :evil:

[330i ZHP]

i almost bought one this week but held off

[HighBoostin330]

Congrats on the progress Stuart! :bow: My sedan counterpart is slowly progressing towards completion. :)

I still need to reinforce my subframe. Been too darn busy. :cry:

[redronin]

so your swapping the rear end out, not rebuilding it?

would you mind mentioning where u got it and a ballpark number? LSD been on my list for years but they are just so damn expensive

[ice330ci05]

so your swapping the rear end out, not rebuilding it?

would you mind mentioning where u got it and a ballpark number? LSD been on my list for years but they are just so damn expensive

it's about 3k :yikes:


goodluck with the project!!!!:thumbsup:

[redronin]

it's about 3k :yikes:


goodluck with the project!!!!:thumbsup:

> insert string of explitives here<


damn thats a lot of money. i suppose its hard to put a price on a lsd, but i just keep thinking 3k.... ok thats a stoptech bbk, a new set of bbs wheels, a new body kit and paint.... an entire new suspension! i envy you who can play with the big dogs. track mods > all other mods.

[fmzip]

Your next tool should be a lift :evil:
Stuart...didn't you have a lift when you did your supercharger installation??

Isn't this you in the pic in your Herman Miller office chair?? :confused:

http://img175.imageshack.us/img175/4233/stuartxf0.jpg

[330i ZHP]

yes about $3000 and they are swapping the flanges on the current 3.46LSD so I can install it on the wagon. I am getting a 3.07 LSD for the sedan to replace the 3.46.

I did have access to a friends lift for the SC install.

I considered (and still am) buying a lift for my garage - but it would have to be a mid-rise lift since I have a standard garage. The mid-rise only lifts the car about 55-60 inches.

[fmzip]

I am even more impressed than I already was with your wrenching skills! I thought that beautiful garage with the lift was your own!!

:bow::bow::bow:

[330i ZHP]

I removed some more parts this evening...no pics yet

[HighBoostin330]

yes about $3000 and they are swapping the flanges on the current 3.46LSD so I can install it on the wagon. I am getting a 3.07 LSD for the sedan to replace the 3.46.

I did have access to a friends lift for the SC install.

I considered (and still am) buying a lift for my garage - but it would have to be a mid-rise lift since I have a standard garage. The mid-rise only lifts the car about 55-60 inches.

So what solidified the decision for you to go back to 3.07? :)

[spartanwarrior]

Congrats, looks fantastic it will be a monster with the TS3:thumbsup: i too am going to order the TS3 kit in a couple months, also my 3,46 lsd is going to be shipped to MK-Motorsport in Germany to have 3,15 gears installed;)

[TxZHP04]

So what solidified the decision for you to go back to 3.07? :)

I think he just had to feed his addiction to modding. :rofl:

Seriously though, I'll be really curious to see what he thinks when it's all complete. I kept my 3.07 when I got my LSD but have always wondered if I made the right decision.

[330i ZHP]

so many of the knowledgeable folks at ess, diffsonline, here and some others all seemed to think the 3.07 would be best

[330i ZHP]

the parts from TMS just arrived - I guess I will go home and take the trunk liners out and prepare for the welding...

I hope to have the diffs back by the end of next week and install the 3.07 back in the sedan. There is an event on May 18th I would like to attend and not just drive the wagon

[phrozen06]

Stuart at his best.

[Lemonsqr]

so many goodies :drool::drool:

[fmzip]

Stuart, do you track your car or just plan to destroy public pavement?? :)

[Nico3k]

Looking fantastic! I love the pile of parts; hope my sedan will one day be as elite as yours is.

BTW can you please take pics when working on the subframe? I need to weld in the reinforcement plates since the metal is starting to fail :(

[330i ZHP]

Here is some work from tonight (only had about an hour to wrench after getting home at 8pm)

http://i225.photobucket.com/albums/dd62/smoulton0204/100_4779.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4780.jpg


Before the rtabs and sleeves

http://i225.photobucket.com/albums/dd62/smoulton0204/100_4778.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4776.jpg


New RTAB's and RTAB sleeves

http://i225.photobucket.com/albums/dd62/smoulton0204/100_4784.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4783.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4782.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4781.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4788.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4785.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4789.jpg


Upper strut reinforcements and the stock strut mount

http://i225.photobucket.com/albums/dd62/smoulton0204/100_4791.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4792.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4793.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4794.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4795.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4796.jpg

[2003330i]

its so sick that you can do all this work yourself. i'm too afraid to mess anything up and have a wheel or something fall off while i'm driving. hahahha

[330i ZHP]

thanks bud - you have to learn somewhere - working on a car is really quite easy...with the right tools and a little common sense

[HighBoostin330]

That is looking good! I need to follow in your footsteps. :bow:

What RSM is that? JTD Performance?

[330i ZHP]

yes sir

[HighBoostin330]

yes sir

Damn, those look better than my GC. Do you have squeaking problems with them?

[330i ZHP]

I am ready to do the welding portion of this project...I am going to regret relying on my friend for the use of his welder...I may just go ahead and go buy one this week

[330i ZHP]

Damn, those look better than my GC. Do you have squeaking problems with them?

dont know - hope not - the car is still in the air...need to weld in the reinforcements and reinstall everything - waiting on the diff

[HighBoostin330]

You gotta make a list of the things you did. I will have to follow in your footsteps. Keep up the good work and updates! :thumbsup:

[mcr_driver]

:drool: at this thread and your knowledge of your car.

subscribed

[fmzip]

That is looking good! I need to follow in your footsteps. :bow:

What RSM is that? JTD Performance?


What does "RSM" stand for?

EDIT: Nevermind RSM=rear shock mount, I have those exact same ones installed in my car. :)

I need to replace my lower ball joints at some point so I see some more goodies to install while I am at it! What are you using for bushings on those camber arms, oem bushings?

[330i ZHP]

yes to oem - wanted to keep the ride decent

[ice330ci05]

Damn, those look better than my GC. Do you have squeaking problems with them?

i have the same ones and they don't squeak,

[fmzip]

I need to add a compressor to my arsenal! Does the rear sway bar really have to come out when you did the camber arms? I remember batting with my rear sway for hours installing that thing! Then again, I didn't drop the exhaust to install it either

These acronyms....what is a "GC"?? :)

[aggieE46]

Ground Control

[330i ZHP]

i have the same ones and they don't squeak,

good to know

I need to add a compressor to my arsenal! Does the rear sway bar really have to come out when you did the camber arms? I remember batting with my rear sway for hours installing that thing! Then again, I didn't drop the exhaust to install it either

These acronyms....what is a "GC"?? :)

not sure - but remember I am completely dropping the suspension and subframe

Ground Control

+1

[dubplaya]

Wow dude you are really getting in there.
Good luck with your build, I'm anxious to see your completed project. :)

Lucky man gets stage 3, a new house and a wife :bow:

pic in the office chair is priceless :rofl:

[330i ZHP]

I love that pic too - plus freddy just hanging out in his pink shirt

[TxZHP04]

yes to oem - wanted to keep the ride decent

When I replaced my RTABs, I bought the UUC urethane and a set of OEM along with Vorshlag shims in case I didn't like the UUC (fear of the unknown). I installed the UUC first, the OEM and shims are still sitting in my garage 6 months later. Certain things, like expansion joints, make more of a thumping noise now but even my wife doesn't think ride comfort has been compromised.

I'm not saying urethane bushings are better and, Stuart, I'm not suggesting you change your plans - shimmed OEM is an excellent setup. But for anyone worried about compromising ride quality with urethane, the change is not all that significant - at least with the UUC bushings, I have no experience with PowerFlex or others.

[aggieE46]

I think he's referring to the bushings on the lower control arm, not the RTABs. I think he went OEM on those. Correct me if I'm wrong.



When I replaced my RTABs, I bought the UUC urethane and a set of OEM along with Vorshlag shims in case I didn't like the UUC (fear of the unknown). I installed the UUC first, the OEM and shims are still sitting in my garage 6 months later. Certain things, like expansion joints, make more of a thumping noise now but even my wife doesn't think ride comfort has been compromised.

I'm not saying urethane bushings are better and, Stuart, I'm not suggesting you change your plans - shimmed OEM is an excellent setup. But for anyone worried about compromising ride quality with urethane, the change is not all that significant - at least with the UUC bushings, I have no experience with PowerFlex or others.

[330i ZHP]

I think he's referring to the bushings on the lower control arm, not the RTABs. I think he went OEM on those. Correct me if I'm wrong.

you are right - remember - my bushings only have 23k miles on them

[TxZHP04]

I think he's referring to the bushings on the lower control arm, not the RTABs. I think he went OEM on those. Correct me if I'm wrong.

Oops... I think I must have been distracted by all the pretty pictures. :rofl:

[aggieE46]

It happens :)

I love these threads.

Oops... I think I must have been distracted by all the pretty pictures. :rofl:

[phrozen06]

Will you be working on your ZHP this saturday? If so I might stop by.

[330i ZHP]

I might be - I may finish up the prep for the welding tomorrow evening and saturday... I have to remove the paint from the areas to be sanded and cut out two access holes in the trunk to get to two spots that need to be welded from the top

[phrozen06]

Ok I'll call and see if you're around.

[sheefo2k]

beautiful as usual stu!!! seriously.. just amazing!!! keep up the work

[330i ZHP]

I did some more tonight for about an hour - finished the passenger side reinforcements and removed the rest of the stuff hanging from the subframe...I cannot get the subframe off - the parking brake cables are holding it up...irk


I had hoped to prep the body surfaces for welding in case I went and bought a welder tomorrow.

Chris and Chris - if I get a welder - I will be welding on Saturday

[SeanC]

:bow: that's how a zhp should be modded...

[jeremysmith1967]

Awesome work. I recently had the turner subframe kit installed on my car along with the turner rtab limiters and the car feels great. Good luck with the rest of the project.

[ssm1991]

You should set up a website like MarvelPhx/Todd. There are a lot of things we can learn from you.

[fmzip]

Awesome work. I recently had the turner subframe kit installed on my car along with the turner rtab limiters and the car feels great. Good luck with the rest of the project.
Just curious, how much did it run you to have the subframe kit installed?

[MarvelPhx]

Stuart:

You are crazy and I love ya for it. You took what I did and went that much farther!

I will say this, I loved my TS2 ZHP, but I drove Brian's TS3 at Bimmerfest... I can only imagine yours on happy 93 octane, cuz Brian's was ridiculous on 91. Such a big difference from TS2 to TS3 and runs so damn smooth! Driving normally, it felt just like stock with a lion waiting under your foot.

Brian has one of the cleanest E46s I have ever seen. And Stuart, don't stop. Don't ever stop!

[TxZHP04]

Just curious, how much did it run you to have the subframe kit installed?

Turner charges about 15 hours labor for this job.

[HighBoostin330]

Stuart:

You are crazy and I love ya for it. You took what I did and went that much farther!

I will say this, I loved my TS2 ZHP, but I drove Brian's TS3 at Bimmerfest... I can only imagine yours on happy 93 octane, cuz Brian's was ridiculous on 91. Such a big difference from TS2 to TS3 and runs so damn smooth! Driving normally, it felt just like stock with a lion waiting under your foot.

Brian has one of the cleanest E46s I have ever seen. And Stuart, don't stop. Don't ever stop!

Thank you for the compliments Todd! :thumbsup:

I didn't even get to full clean my car before the 'Fest. I just ended up wiping down only the front end. :rofl:

Nice to show and hang out with ESS during Bimmerfest! :)

[330i ZHP]

Here is tonights efforts - I can start putting everything back together tomorrow. Thank you very much to Q for coming with his welder and expertise in welding.

Reinforcement plates
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4797.jpg

Panels that had to be cut out - and the new panels to replace after welding in the trunk.
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4798.jpg

Holes in the trunk
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4799.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4800.jpg

Subframe cleaned and ready to go back in the car
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4803.jpg

Body prep before welding
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4807.jpg


Welded panels
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4811.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4812.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4813.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4823.jpg


Welding

http://i225.photobucket.com/albums/dd62/smoulton0204/100_4805.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4806.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4819.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4809.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4810.jpg

[330i ZHP]

more:

Panels painted and ready to reinstall everything tomorrow (well, later this AM)

http://i225.photobucket.com/albums/dd62/smoulton0204/100_4824.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4825.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4826.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4827.jpg

[330i ZHP]

:drool: at this thread and your knowledge of your car.

subscribed

thank you

Wow dude you are really getting in there.
Good luck with your build, I'm anxious to see your completed project. :)

Lucky man gets stage 3, a new house and a wife :bow:

pic in the office chair is priceless :rofl:

thanks danny

beautiful as usual stu!!! seriously.. just amazing!!! keep up the work

i am trying

:bow: that's how a zhp should be modded...

agreed

Awesome work. I recently had the turner subframe kit installed on my car along with the turner rtab limiters and the car feels great. Good luck with the rest of the project.

looking forward to a firm rear - oh you meant the car...lol

You should set up a website like MarvelPhx/Todd. There are a lot of things we can learn from you.

Todd has that covered - i would be glad to offer write-ups to his site but I am not going to run my own

Stuart:

You are crazy and I love ya for it. You took what I did and went that much farther!

I will say this, I loved my TS2 ZHP, but I drove Brian's TS3 at Bimmerfest... I can only imagine yours on happy 93 octane, cuz Brian's was ridiculous on 91. Such a big difference from TS2 to TS3 and runs so damn smooth! Driving normally, it felt just like stock with a lion waiting under your foot.

Brian has one of the cleanest E46s I have ever seen. And Stuart, don't stop. Don't ever stop!

Thank you todd - I have a little extra tidbit coming from ESS in a few weeks...the wagon was feeling lonely

Turner charges about 15 hours labor for this job.

Yup - I was quoted about $1300-1500 for labor - so I saved a ton doing this myself

[330i ZHP]

Everything reinstalled - thank you again Q for dropping what you were doing last night and coming over to weld the parts so I didnt have to wait until next weekend to do all this.


http://i225.photobucket.com/albums/dd62/smoulton0204/100_4832.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4833.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4834.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4831.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4839.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4840.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4835.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4837.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4836.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4843.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4842.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4844.jpg


this is all that is left to reinstall - again, I have to wait for the new Dif

http://i225.photobucket.com/albums/dd62/smoulton0204/100_4846.jpg


And I think the wagon feels a little lonely - so i semi-washed her

http://i225.photobucket.com/albums/dd62/smoulton0204/100_4847.jpg

[m330]

how did i miss this thread?!!?! :yikes:

looks like everything is coming together man! good luck w/ the rest of the install stuart!

cant wait to see it done!



EP FTW! :P

[apollotrance1]

what did you paint the panels with?

[330i ZHP]

what did you paint the panels with?

I painted them first with krylon metal primer then with krylon gloss black

[mcr_driver]

nice job stuart what type of welding did you do oxy/acetaline?MIG or TIG? i think once i do a tranny swap i will do reinforcements then so i can run more boost on my technik charger :4ngie:

give us a review once your back on the road and let us know how it feels :thumbsup:

[BartenderPlease]

Didn't see this thread 5 days ago. Stu, you and MITE46 will have my two favorite sedans on the site. :bow:

[jeremysmith1967]

Nicely done with the reinforcements.

and a firm rear is good in all applications.

[330i ZHP]

nice job stuart what type of welding did you do oxy/acetaline?MIG or TIG? i think once i do a tranny swap i will do reinforcements then so i can run more boost on my technik charger :4ngie:

give us a review once your back on the road and let us know how it feels :thumbsup:

Mig welding - I guess soon I will have no more reasons not to go ahead and pull the engine and get the big project under way

Didn't see this thread 5 days ago. Stu, you and MITE46 will have my two favorite sedans on the site. :bow:

Thank you bud

Nicely done with the reinforcements.

and a firm rear is good in all applications.

I like firm rears - oh, you meant the car...yes, of course

[TotumDependeate]

nice work

[330i ZHP]

i am glad I finished everything up yesterday - between mothers day stuff and then constant raining today....since i prefer to work with the garage door open

[m330]

raining FTL

sunny 74 out here in cali FTW :D

im excited for you man!

[330i ZHP]

you Californian's and your sun - thanks bud, to the hotest looking 4dr

[mcr_driver]

i think you give pat a run for his money in the hot sedan department :rofl:

did you rent the MIG welder or did you buy one?? if you don't mind me asking that is...

[db-330Ci]

nice modifications - congrats on the future TS3... :thumbsup:

ESS TS2/3 on my 3.3l :hmm:

Daniel

[HighBoostin330]

nice modifications - congrats on the future TS3... :thumbsup:

ESS TS2/3 on my 3.3l :hmm:

Daniel

I think you would need to go back to a 3.0L for the TS3. Ask AJ to make sure. A 3.3L TS3 would be very interesting. :4ngie:

At least you are closer to ESS than we are. :(

[330i ZHP]

i think you give pat a run for his money in the hot sedan department :rofl:

did you rent the MIG welder or did you buy one?? if you don't mind me asking that is...

Iwas going to buy one - and still will. But a buddy came over with his and he did the welding (he used to be a welder in a ship yard).

[330i ZHP]

3.46LSD is back - trying to decide whether I want to install it in the wagon tonight or wait, since the sedan is stuck in the garage with no diff

[HighBoostin330]

3.46LSD is back - trying to decide whether I want to install it in the wagon tonight or wait, since the sedan is stuck in the garage with no diff

Was the 3.46LSD reconditioned or something for the wagon?

3.07LSD for the ZHP right? :)

[330i ZHP]

the input and output shafts had to be swapped for the 325 units instead of the 330 pieces...it only has about 10k miles on the diff and they said everything looked perfect inside.

It worked great in the sedan and it is now in the wagon as of tonight - it works perfectly.

The new (kind of) and the old:

http://i225.photobucket.com/albums/dd62/smoulton0204/100_4848.jpg


Having to work in the driveway and I found out I need to buy two more jack stands - I thought I had four...hmmm, I wonder if I ever did or what happened to them...

http://i225.photobucket.com/albums/dd62/smoulton0204/100_4850.jpg


Found this little (BIG ASS) bubble....I guess the Toyo's will have to be put on the wagon sooner than I expected....damn pot holes

http://i225.photobucket.com/albums/dd62/smoulton0204/100_4851.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4852.jpg

[330i ZHP]

Was the 3.46LSD reconditioned or something for the wagon?

3.07LSD for the ZHP right? :)

yes to 3.07lsd and the 346 just needed the flanges swapped

[HighBoostin330]

yes to 3.07lsd and the 346 just needed the flanges swapped

Sorry if it came late, but Jim got back to my email. I don't know if this helps you right now or not.

Brian,
Attached are 4 charts covering 3.46, 3.23, 3.15 and 3.07 final drive ratios.

Basically, what happens with different ratios is you move your best pulling mph range ( 3rd gear between 4500 and 6500) incrementally higher with each taller ratio.
For example, if you would prefer your 3rd gear range ( 60 -88 mph) was significantly higher, then the 3.07 would place it in the 78 to 98 mph range. This would eliminate you 1st gear wheel spin as well.
Ideally, for the best performance you want to be just below wheel slip at all times during acceleration, so if one could try all four and choose the one that meets that criteria, life would be good.

Jim

[jeremysmith1967]

Wow thats a huge bubble!!! I had one on the same wheel and the bubble was actually hitting the shock. Needless to say I had to buy a new tire.

[330i ZHP]

Wow thats a huge bubble!!! I had one on the same wheel and the bubble was actually hitting the shock. Needless to say I had to buy a new tire.

yea it sucks - i have a set of toyos that I took off the lm's - but i wanted to use up every last mile on the gsd3's...maybe I will check with the used tire places for just the one used tire and save the four toyos

[fmzip]

Stuart, do you track your car or just plan to destroy public pavement?? :)

I was curious if you do track your car....I'm trying to get ideas on LSD setups and which one to go with.

[330i ZHP]

I have taken the sedan auto-x'ing - but no serious track time. The LSD is one of my favorite upgrades. So much so, that I just put the 3.46lsd from the sedan on the wagon and bought another unit from Dan @ diffsonline. He isnt the cheapest or the most expensive...but a damn great product.

[smokedOUTbimmer]

Hey, if this is too personal then feel free to just not answer, and don't take this the wrong way. But what do you do for a living where you can own 2 BMW's, mod them, AND know how to do all this stuff yourself?

I ask cuz I'm young, I work on my own cars and have been considering my career in auto mechanics, but I know that I probably won't be making more than 60K a year. How do you do it? lol

Awesome cars, btw.

[330i ZHP]

I am an IT manager who made the choice between working with computers instead of with cars about 11 years ago. I love working with my hands, I hate paying someone to do what I can do, I am very competent and have natural ability to learn/figure things out, and most importantly...it is therapy for me to know everything about my cars, house, computers, you name it....I should probably be an engineer...but I suck at math

By not paying some shop $1800 to do the rear suspension/body reinforcements on the car - I am able to put that money into other projects - this is of course an example. Or the $3000+ I was quoted to install the SC...that paid for almost all the mods on the wagon.

As you well know, by working on the car yourself, if something goes wrong, you usually know exactly where and what to look for and fix. Also, I found that when I did let someone work on a car of mine, I ended up having problems with the same part or with a related part....and I got tired of going back and complaining or having to diagnose what they f*cked up. Example, get the car dyno'ed and they bend my control arms...adjust the bung on the exhaust and leave the bolts off and the damn exhaust almost falls off on the way home...IRK...these people are supposed to be the pros

thank you for the compliment and keep on modding and doing the work yourself...I respect folks that know their cars and appreciate their mods more if I know they did the work themselves and didnt just pay someone....

To those of you that are not mechanically inclined and have the money to pay others - I mean no disrespect...I still appreciate your mods

[330i ZHP]

I received the diff yesterday and will be installing it tonight - so the car will be back on the road

ALSO******************

hot damn - I found myself an M54 3.0 motor with 24k miles out of a Z4 (that is extra cool because it has the same oil pan and oil pump - although I have a new pump to install) and the car is a rear end hit...SWEET!!!!!!! and a decent price too. Oh yea and they will deliver to my house and help me put it on the engine stand

[330i ZHP]

they will gaurantee that everything is perfect with the motor - and I am going to there tomorrow to see the motor still in the car and I can start the car and it drives..kinda drives...but the important part is I can start the car and listen to it

[TxZHP04]

I received the diff yesterday and will be installing it tonight - so the car will be back on the road

ALSO******************

hot damn - I found myself an M54 3.0 motor with 24k miles out of a Z4 (that is extra cool because it has the same oil pan and oil pump - although I have a new pump to install) and the car is a rear end hit...SWEET!!!!!!! and a decent price too. Oh yea and they will deliver to my house and help me put it on the engine stand

So are you planning to build the Z4 motor and then swap it in to minimize your down time during the TS3 build? Nice.

[sillieidiot]

I am an IT manager who made the choice between working with computers instead of with cars about 11 years ago. I love working with my hands, I hate paying someone to do what I can do, I am very competent and have natural ability to learn/figure things out, and most importantly...it is therapy for me to know everything about my cars, house, computers, you name it....I should probably be an engineer...but I suck at math

By not paying some shop $1800 to do the rear suspension/body reinforcements on the car - I am able to put that money into other projects - this is of course an example. Or the $3000+ I was quoted to install the SC...that paid for almost all the mods on the wagon.

As you well know, by working on the car yourself, if something goes wrong, you usually know exactly where and what to look for and fix. Also, I found that when I did let someone work on a car of mine, I ended up having problems with the same part or with a related part....and I got tired of going back and complaining or having to diagnose what they f*cked up. Example, get the car dyno'ed and they bend my control arms...adjust the bung on the exhaust and leave the bolts off and the damn exhaust almost falls off on the way home...IRK...these people are supposed to be the pros

thank you for the compliment and keep on modding and doing the work yourself...I respect folks that know their cars and appreciate their mods more if I know they did the work themselves and didnt just pay someone....

To those of you that are not mechanically inclined and have the money to pay others - I mean no disrespect...I still appreciate your mods

wow sounds like i'm following in your footsteps. i made the same decision like last year and am currently going to school for MIS. decided to do this to fund my hobbies

[phrozen06]

I received the diff yesterday and will be installing it tonight - so the car will be back on the road

ALSO******************

hot damn - I found myself an M54 3.0 motor with 24k miles out of a Z4 (that is extra cool because it has the same oil pan and oil pump - although I have a new pump to install) and the car is a rear end hit...SWEET!!!!!!! and a decent price too. Oh yea and they will deliver to my house and help me put it on the engine stand

you got to let me know when you're doing the swap so that I can witness this in person.

[330i ZHP]

So are you planning to build the Z4 motor and then swap it in to minimize your down time during the TS3 build? Nice.

exactly - and if everything goes well....hmmm, I am thinking the wagon will get a ZHP motor swapped in...Aj, has already heard the plan and he says it will work. That might give me the only 330i Touring (maybe going to swap in a 6spd as well) in the states

you got to let me know when you're doing the swap so that I can witness this in person.

I want to do the diff tonight - is that what you mean? Or when I pull the motor from the sedan?

[phrozen06]

I want to do the diff tonight - is that what you mean? Or when I pull the motor from the sedan?

when you pull the motor out of the sedan.

[phrozen06]

I want to do the diff tonight - is that what you mean? Or when I pull the motor from the sedan?

when you pull the motor out of the sedan. Plus aren't you putting the M54 out of the Z4 in the Touring provided the engine is ok?


***Stupid double posts***

[2000_328CI]

Stu your car is soooo nasty :evil:

[330i ZHP]

when you pull the motor out of the sedan. Plus aren't you putting the M54 out of the Z4 in the Touring provided the engine is ok?


***Stupid double posts***

No, I would be putting the Z4 motor in the sedan and the zhp motor in the wagon

[TxZHP04]

exactly - and if everything goes well....hmmm, I am thinking the wagon will get a ZHP motor swapped in...Aj, has already heard the plan and he says it will work. That might give me the only 330i Touring (maybe going to swap in a 6spd as well) in the states

You know, swapping in the 3.0L and a 6 spd would open the door to a TS on the Touring. :4ngie:

[330i ZHP]

lol, I am already 99% sure I am doing the TS1 in the wagon with the ability to go TS2 if I do the trans swap - but I need to wait until August or September

[fmzip]

Congrats on the score Stuart!! Love the concept of building an engine up and doing the swap!

[330i ZHP]

the sedan is back together - I have to adjust the dust shield on the drivers side - it is rubbing the rotor

[330i ZHP]

Ok, so I have managed to lose the wheel lock key for my wheel locks on the sedan. I think I left it on one of the wheel locks the other night after hours of re-installing the rear suspension and diff and then went for a test drive. I have searched high and low and walked the entire path I took a short drive with the other night...I cannot find it anywhere and I only had one (dont ask)...anyway, cant fix the dust shield so I cant drive the damn car.


On better news, I bought a (well most of it) a wrecked ZHP. So I now have a spare motor to disassemble and build up for the TS3. Once the sedan is up and running 100% - I will then swap the zhp 3.0 from my car into the wagon and get rid of the 2.5L...I am also strongly considering swapping out the automatic and installing the 6spd and driveshaft into the wagon. This would be a really cool car - a 330iT with 6spd...not sure how many if any have been made - and it is likely to be the only in the states.

[elite53]

That sucks about the wheel lock but it is kind of nice to know even superhero mechanics like Stuart make mistakes sometimes. :rofl:

[330i ZHP]

thanks bud...i feel stupid and pissed all at the same time.

[elite53]

Don't...... Iv'e done much worse. I once went to set my car down off the jackstands but didn't pull them out from under the car far enough and when I let the jack down I tore a big hole in my sideskirt with the jackstand. :banghead: I hate it when damage to my car is self inflicted. :tsk:

[kevinterkelsen]

Hi Stuart,

my car was a 328ci (m52tu - double vanos) automatic - we took the 3.0 l m52 single vanos (bulid by ESS) from my wrecked car and installed it, it fits a e36 m3 manual gearbox (2000 usd) and a new shaft to the rear differential (200 usd) - and then the car was a manual.

Looking forward to getting a new radiator - the automatic has a cooling device for the transmssion integrated in the radiator - getting a clean manual radiatior propably will not give me anything in either cooling or HP- but it will look cleaner in the engine bay - i guess that counts for something :o)

Best,

Kevin

[ThunderRobo]

Wow, congrads on the build!

You got some mad skillz' that i wish i will some day have! :bow::bow:

[330i ZHP]

thanks bud

[330i ZHP]

The twins:

http://i225.photobucket.com/albums/dd62/smoulton0204/100_4858.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4857.jpg

And my new parts for the big PROJECTS:

http://i225.photobucket.com/albums/dd62/smoulton0204/100_4861.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4872.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4868.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4869.jpg


http://i225.photobucket.com/albums/dd62/smoulton0204/100_4870.jpg

The difference between the ZHP and BMW Performance shifters:

http://i225.photobucket.com/albums/dd62/smoulton0204/100_4871.jpg




And the new real new parts:

http://i225.photobucket.com/albums/dd62/smoulton0204/100_4862.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4866.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4867.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4863.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4864.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4865.jpg

[AntB]

Which car is the engine for? And why did you need a new engine??? Maybe I missed something in this thread!

[330i ZHP]

Neither car needs a new motor. I am going to use the spare engine to build up the TS3 (instead of using my current motor). This will decrease the downtime and save my low mileage motor in case something goes wrong. If everything goes well, then I will install the motor I am saving from my sedan into the wagon (replacing the perfectly good 2.5L).

If I do the engine swap in the wagon, then I will also swap in the 6spd for the automatic it has now.

Make sense? It is potentially two big projects

[BartenderPlease]

Sick dude :)

[330i ZHP]

stripped the motor today and ready to start taking apart the block and head tomorrow - i will post some pics later

[330i ZHP]

So I made a tool to get the wheel locks off:

http://i225.photobucket.com/albums/dd62/smoulton0204/100_4919.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4920.jpg

[Minnoe07]

Wow.... and it's that easy to steal wheels with locks on them. :censor:

[330i ZHP]

yep

[sheefo2k]

your ****ing nuts stu!!! and I love it

[330i ZHP]

The teardown:

http://i225.photobucket.com/albums/dd62/smoulton0204/100_4873.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4882.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4886.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4887.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4888.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4889.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4891.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4895.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4896.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4899.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4900.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4903.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4909.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4910.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4911.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4912.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4913.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4915.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4916.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4917.jpg

[330i ZHP]

http://i225.photobucket.com/albums/dd62/smoulton0204/100_4918.jpg

[Nismode]

I am an IT manager who made the choice between working with computers instead of with cars about 11 years ago. I love working with my hands, I hate paying someone to do what I can do, I am very competent and have natural ability to learn/figure things out, and most importantly...it is therapy for me to know everything about my cars, house, computers, you name it....I should probably be an engineer...but I suck at math

By not paying some shop $1800 to do the rear suspension/body reinforcements on the car - I am able to put that money into other projects - this is of course an example. Or the $3000+ I was quoted to install the SC...that paid for almost all the mods on the wagon.

As you well know, by working on the car yourself, if something goes wrong, you usually know exactly where and what to look for and fix. Also, I found that when I did let someone work on a car of mine, I ended up having problems with the same part or with a related part....and I got tired of going back and complaining or having to diagnose what they f*cked up. Example, get the car dyno'ed and they bend my control arms...adjust the bung on the exhaust and leave the bolts off and the damn exhaust almost falls off on the way home...IRK...these people are supposed to be the pros

:rofl: I can really relate to what you say... I'm majoring in Mechanical engineering in college, and hope to be part of the Formula SAE team at my school so that I can learn as much as I can so that I can work on my own car, although I'm afraid of breaking things electronically related (although I'm technologically inclined).. So far this weekend, I've bricked my iTouch, nearly fried my external Seagate HDD (bad reviews), have been dealing with a broken laptop for almost 5 months, and looking to get a new one this summer.

I'm gonna have to come to DC to witness this, and also maybe learn some stuff from you :4ngie:

I'm looking for a CIA internship/scholarship that places me in DC for the next few summers...that'd be sick to get.

[330i ZHP]

oohh, CIA - I cant talk to you then...eeek

[Mike Benvo]

Absolutely incredible. Keep us updated, and thanks for posting this thread!

[2003330i]

stu,
the pic you have of the comparing the zhp vs bmw shifter: which is the ahp one? is it the one on top?

[330i ZHP]

stu,
the pic you have of the comparing the zhp vs bmw shifter: which is the ahp one? is it the one on top?

Yes, I will try the "short-shift" kit when I do the re-build and see if there is any difference. I have a funny feeling it would be more noticeable coming from no sport shifter to this one.

[m330]

amazing STU!

you have by far the cleanest e46 sedan. :bow:

gets me motivated to do some hardcore DIY action myself haha...

[Mo_Zhp]

OH man, can't wait to do what your doing in a few year! Both of your cars are amazing!

[2000_328CI]

stuart, you're out of this world man :bow: awesome modding :thumbup:

[Lemonsqr]

This is looking like a really fun project!!! Have fun!

[fmzip]

Looking good Stuart.....what about having the engine balanced? Yes/No?

[330i ZHP]

Absolutely incredible. Keep us updated, and thanks for posting this thread!

thanks Mike

amazing STU!

you have by far the cleanest e46 sedan. :bow:

gets me motivated to do some hardcore DIY action myself haha...

You my man, you have the best looking sedan

OH man, can't wait to do what your doing in a few year! Both of your cars are amazing!

good luck - it is fun to do the work yourself and it is kind of therapeutic for me
stuart, you're out of this world man :bow: awesome modding :thumbup:

Thanks chase

This is looking like a really fun project!!! Have fun!

I am

Looking good Stuart.....what about having the engine balanced? Yes/No?

Yes it will, as well as being prepped and inspected for any issues. The heads will get the intake and exhaust ports opened up and other various things

[fmzip]

It's been a long time since I had an engine balanced, what's involved with that? Do you need to give a shop the crank rods, pistons and flywheel?

[330i ZHP]

all items that make up the rotating mass inluding the items you listed, the crank and balancer

[db-330Ci]

Wow, respect for that project ... :drool:

Best regards, Daniel

[2003330i]

Yes, I will try the "short-shift" kit when I do the re-build and see if there is any difference. I have a funny feeling it would be more noticeable coming from no sport shifter to this one.

i didn't even know bmw had a short shifter. if you dont mind me asking how much did you pay for it?

[330i ZHP]

http://i225.photobucket.com/albums/dd62/smoulton0204/100_4921.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4922.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4923.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4924.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4925.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4926.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4927.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4928.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4929.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4930.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4931.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4934.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4935.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4933.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4936.jpg

the painted floor in my garage was already bad - but the chemicals in the engine (oil and anti-freeze) and the cleaning chemicals are stipping more paint off the floor - luckily I am planning to install floor tiles in the garage

http://i225.photobucket.com/albums/dd62/smoulton0204/100_4932.jpg

[330i ZHP]

interesting thing to note for those of you with hopes of your engine lasting forever....the retaining nut on the oil pump was loose when I went to take the oil pump off the motor...I will definetely be welding the nut onto the shaft/gear

[TxZHP04]

interesting thing to note for those of you with hopes of your engine lasting forever....the retaining nut on the oil pump was loose when I went to take the oil pump off the motor...I will definetely be welding the nut onto the shaft/gear

This seems to happen all too often. IIRC, pei330ci found the same thing when tearing down his engine. You might do some more research on this subject. It seems like welding the nut may have its own negative consequences... not that I recall exactly what that might be at the moment. I'd PM pei330ci and see what he has to share on the subject.

[330i ZHP]

I will - thanks

[TxZHP04]

It's pei330ci by the way. I forgot the 'c' in his user name.

[330i ZHP]

i found it and PMd him

Walter at VMWerks welded the nut on for Brian on his TS3

[elite53]

Wow Stuart !!! This is :drool::drool::drool: I can only dream of following in your footsteps one day. I already have the same ladder and shelves as you so I guess I'm on my way? :rofl::rofl::rofl:

[UncleDon]

Subscribing for all the great pictures...:hi:

[elite53]

Yes, please keep the car porn ...Uh, I mean pictures... coming so we can all enjoy this process with you.

[Titan 3]

I'm glued to this one!!! Nice werk, sir!! EP FTMFW!

[330i ZHP]

probably wont get any work done today or tomorrow - more updates this weekend

[aggieE46]

It's great to see someone else digging into the M54. The vicious lies spread about BMW engines being impossible for the average joe to work on are coming out. Cams CAN be removed without $2000 in BMW tools, turbo kits are becoming available, individuals can tune their own cars (Shark Edit).

It's a good time to own a non-M right now.

Keep it up.

[330i ZHP]

thanks - I am going to tackle the cams this weekend (without the tool). I have the vanos tools but not the cam pressure thingy...

I hope the method in pelican DIY tips works any other ideas???? Please feel free to share.

[simsima325]

u know who to call if u need an extra hand, or u get stuck under the car or something ;) only a few min away!

[aggieE46]

That's exactly the DIY I'm going to use. I think that between that and the Bentley, it should be fine. At least if you have the head off, you don't have to worry about the valves hitting the pistons. You'll be fine.

thanks - I am going to tackle the cams this weekend (without the tool). I have the vanos tools but not the cam pressure thingy...

I hope the method in pelican DIY tips works any other ideas???? Please feel free to share.

[n2Bimmer]

wow this is sick, props, good luck, gives me hope for my sedan, to bad its not a zhp. ahhh

[pei330ci]

I've been busy; just got a chance to read through the thread so far.

Great project, keep the pictures and comments coming.

PS. You should have bought your own welder. :craig:

[330i ZHP]

just about finished tearing down the motor - just need to remove the crank and pistons

Then off to the machine shop.

I am fearful that the exhaust cam and number 7 bearing at scored a little too much - I need to talk to the pros

I will post pics shortly

[330i ZHP]

http://i225.photobucket.com/albums/dd62/smoulton0204/100_4937.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4949.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4950.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4951.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4954.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4955.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4956.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4957.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4958.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4960.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4962.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4963.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4965.jpg



This might not be good news:

http://i225.photobucket.com/albums/dd62/smoulton0204/100_4952.jpg
http://i225.photobucket.com/albums/dd62/smoulton0204/100_4953.jpg

[330i ZHP]

that scoring is only on cam bearing number 7 of the exhaust...so I will ahve to look at my ZHP cams from my car and see if they are any different or better and go with new bearings and the better of the cams in the wagon.

I have to swap the cams from the sedan into this motor

[ritos530i]

Stu,
Nice job on the build and I finally finished reading everything.
If you want to get together and help me rebuild my other M54 motor let me know :)

Great Fxxxing Job and all props goes out to you.

Rito

[330i ZHP]

Local to DC request......

I need to choose a machine shop to do the minor work to the heads, block and the rotating mass parts...I have a couple of folks mentioning
Burtonsville Performance Machine Service
5210 Minnick Rd
Laurel, MD 20707-3138
(301) 384-3595

Ironically that shop is mentioned along with Mancini Machine in Baltimore where I had some horrible work done on a Chevy motor...so I am starting to get that shitty feeling I have made a really bad mistake for opening up a motor to issues.

Does anyone here have actual experience with a shop and how long ago, how much work done and what where the results

[3rd_collective]

Nice work so far Stu! I gotta come by and check out the engine, maybe I'll learn something ;)

[ritos530i]

Stu,
I can give you information on the guy whom built my motor but he is in TX. Let me know and i will give you the details. I have my motor completely built and my head. My head flow tested at 263 with the work i had done. It was a M54B30 block.
Let me know
Rito

Local to DC request......

I need to choose a machine shop to do the minor work to the heads, block and the rotating mass parts...I have a couple of folks mentioning
Burtonsville Performance Machine Service
5210 Minnick Rd
Laurel, MD 20707-3138
(301) 384-3595

Ironically that shop is mentioned along with Mancini Machine in Baltimore where I had some horrible work done on a Chevy motor...so I am starting to get that shitty feeling I have made a really bad mistake for opening up a motor to issues.

Does anyone here have actual experience with a shop and how long ago, how much work done and what where the results

[aggieE46]

No issues getting the cams out? That's great.

It does look a little worn. I wonder if it can be polished up. Although, you're probably more worried about the head than the cam, huh?

Happy with everything else?

Oh, and you have me worried about my oil pump nut.

[330i ZHP]

No issues getting the cams out? That's great.

It does look a little worn. I wonder if it can be polished up. Although, you're probably more worried about the head than the cam, huh?

Happy with everything else?

Oh, and you have me worried about my oil pump nut.

Interestingly the lower cam bearings all look great. It is just that one upper bearing cap and of course the bearing portion of the cam

[fmzip]

Interestingly the lower cam bearings all look great. It is just that one upper bearing cap and of course the bearing portion of the cam

That scoring I assume will be an issue.....

Oh, and you have me worried about my oil pump nut.

I'm actually hoping my oil pump nut dislodges then I'd have legitamite reasons to give to the GF for going to a ts3:thumbsup:

:)

[330i ZHP]

LOL about the TS3

I am curious to see the bearing surfaces on the sedan and wagon for comparison. But I have heard of scoring issues on other ZHP's - but I think that is likely been more documented because of the ZHP cam/VANOS rattle issues...so people are having the cams looked at by BMW dealers along with all the other VANOS problems

[fmzip]

That engine you are tearing down is not a ZHP, right?

[330i ZHP]

yes it is

[aggieE46]

I thought it was from a Z4?

I was actually just thinking about the rattle. And wondered if that could be the issue. I know it's generally in the ZHP, but wondered if the noise didn't occur in the regular MS45 simply because of the less aggressive cam. I know that even non-ZHP guys tend to get the rattle when they install Schrick cams.

[330i ZHP]

I ended up getting a complete ZHP drivetrain instead of the Z4 - for $2300 more, I got the complete engine instead of a long block, the accessories, the wiring harnesses, airbox, 6spd transmission, driveshafts, differential, half shafts, all four 330 brake assembles and the rear trailing arms....oh yea, and all the parts needed to convert the wagon to 6spd


the block is done - I shot home at lunch and pulled the crank and pistons. Everything is ready to go to a machine shop. Hopefully I will have everything ready to start re-assembly in three weeks.

The block, bearings and everything in the bottom end look great - the cylinder walls even have cross hatch still. So likely the only thing being done to the block will be cleaning it up.

I will start tonight assembling the rods to the new pistons and have those ready to be balanced.

[330i ZHP]

I thought it was from a Z4?

I was actually just thinking about the rattle. And wondered if that could be the issue. I know it's generally in the ZHP, but wondered if the noise didn't occur in the regular MS45 simply because of the less aggressive cam. I know that even non-ZHP guys tend to get the rattle when they install Schrick cams.

my sedan has the shrick cams and they rattle just as bad as the ZHP cams...actually, I think it is the VANOS making the noise.

I installed the Dr. VANOS and it drastically reduced the noise, but did not get rid of it.

[fmzip]

Nice score on the whole drivetrain.......still trying to decide 3.38 or 3.46LSD, a six speed would make my decision very simple!

[aggieE46]

So, do you have 2 spare sets of ZHP cams, now? Hint hint... :)

[330i ZHP]

yes i do - but not sure how the exhaust bearing number 7 is yet.

[aggieE46]

Ahh, that reminds me. How was the cam removal? Were you sweating bullets? Did the walkthrough help? Let me know your thoughts. I'm hoping to be able to leave the head on while I do it. Certainly that's a possibility.

[330i ZHP]

it was very straight forward and Due to the lack of space to get to the head bolts with the cams in the way - I decided to remove the cams prior to removing the head. So it is likely that I would not have had any problems swapping the cams while the engine was still in the car.

I know when they installed the shrick cams - the head was still on the motor and they didnt use the special cam tensioner tool

[aggieE46]

Great, thanks. I feel better about it all the time.

[MarvelPhx]

I am so impressed! Keep up the good work and the info here!

[330i ZHP]

Thanks Todd - I am thinking about having ESS send me the black intake setup for the TS3 and keep the current TS2 setup intact for the wagon

[HighBoostin330]

Thanks Todd - I am thinking about having ESS send me the black intake setup for the TS3 and keep the current TS2 setup intact for the wagon

I think I have started a trend. :craig:

[TxZHP04]

I think I have started a trend. :craig:

:D

[m330]

omg holy crap stu!

you are my hero sir! :bow:

[330i ZHP]

thanks - taking everything to the machine shop tomorrow - hopefully they will have everything done by the time I get back from my honeymoon

[GunMoto]

WOW, Pat just linked me to this thread...and it's the first time reading through it today.

I think you're doing fantastic work Stuart, and very well impressed that you've been patient to take so many shots during your build. This thread is like a fairy tale story to tell children at bed time for years to come!! :rofl: :thumbup:

I've been waiting for a thread like this to come through...technical threads have been lacking for some time. :bow:

[330i ZHP]

thanks - I am not much for writing the steps - but I can do pics....I am not posting all the pics, as many are really for me so I can remember how to put things back if I have questions. This is of course along with the Bentley manual, the TIS, the ETK, the WDS, etc

Do you do your own installs? - Looks like you have some major suspension mods.

[330i ZHP]

I received good news today - the scoring on the bearing and cam is nothing to worry about - they are going to polish the scratches and confirm the bearing specs - but the machine shop and a local race shop said not to worry.

[HighBoostin330]

I received good news today - the scoring on the bearing and cam is nothing to worry about - they are going to polish the scratches and confirm the bearing specs - but the machine shop and a local race shop said not to worry.

Yay! :excited:

[330i ZHP]

everything will be ready to assemble in about 3 to 4 weeks (just in time for me to get home)

[fmzip]

I received good news today - the scoring on the bearing and cam is nothing to worry about - they are going to polish the scratches and confirm the bearing specs - but the machine shop and a local race shop said not to worry.


That's great news! you must have been pleasantly surprised!

[330i ZHP]

yep - although these are the cams that will go into the wagon. I will have to have him make certain the schrick cams are ok if I find any damage on them.

[budman]

I love you!! in a non h<sp>o<sp>m<sp>o way

:)

[330i ZHP]

miss you already G - we will miss you next weekend of course and this sunday at the wounded soldiers.

[budman]

yea good luck next weekend. A big step in life :) best of luck

[aggieE46]

Best thing I ever did :)

Good luck! And congratulations.

yea good luck next weekend. A big step in life :) best of luck

[m330]

thanks - taking everything to the machine shop tomorrow - hopefully they will have everything done by the time I get back from my honeymoon

have fun on your honeymoon stuart! :thumbsup:

[330i ZHP]

thanks

I didnt get anything done with cars today - actually had to deal with wedding and family stuff

Maybe tomorrow I will start cleaning the parts from the spare motor

or the 330 brake parts to prep for paint before installing on the wagon. I am actually considering not doing any car work this week to give my hands a break so they dont look dirty or cut up at the wedding...

[budman]

booo

[Lemonsqr]

thanks

I didnt get anything done with cars today - actually had to deal with wedding and family stuff

Maybe tomorrow I will start cleaning the parts from the spare motor

or the 330 brake parts to prep for paint before installing on the wagon. I am actually considering not doing any car work this week to give my hands a break so they dont look dirty or cut up at the wedding...

Thats what white gloves are for...along with the tophat, monocle and cane to go with the outfit :rofl:

[clean-m-tech330]

Looks good!! Any idea on what final numbers should be?

-Chris

[db-330Ci]

btw. what oil do you fill in the TS2/TS3 ...?

Daniel

[330i ZHP]

420ish + at the rear wheels

[330i ZHP]

btw. what oil do you fill in the TS2/TS3 ...?

Daniel

i thnk it is the same oil they recommend in the m3

[HighBoostin330]

420ish + at the rear wheels

Holy Cow! How much boost are you planning to run? :yikes: :bow:

[330i ZHP]

def 15psi and maybe 16psi

[budman]

back from the honeymoon yet? We need updates :)

[m330]

back from the honeymoon yet? We need updates :)

+1!!!

[Brian N]

back from the honeymoon yet? We need updates :)

+2!!! I am dying over here.

[330i ZHP]

i am back from the cruise but still in Waikiki. Hawaii is great (i dont think i could live here though). I a flying home Wednesday and will be recovering for a day or two. I plan to go by the machine shop for a status update or hopefully pick up all the parts. I havent heard from them and the agreement was, I wouldnt unless there were any problems...so I am assuming that means good stuff.

I need to check with Aj to see when they are shipping the other SC. I told them to hold off before I left in case I blew too much on this trip.

[asianjedi]

Subscribed

[330i ZHP]

all black ts intake, charger, ps res....etc is being prepared for the sedan ts3 engine build. that way the wagon will get the partially alum intake ts setup.

spoke to thw machine shop and everything should be ready for delivery early next week.

installing arp head studs and rod and main bolts for added strength

[HighBoostin330]

all black ts intake, charger, ps res....etc is being prepared for the sedan ts3 engine build. that way the wagon will get the partially alum intake ts setup.

spoke to thw machine shop and everything should be ready for delivery early next week.

installing arp head studs and rod and main bolts for added strength

AJ said that caused the head to lift off the block, so just beware.

[330i ZHP]

really? hmmmm, maybe i will stop that order

thanks, aj, any comment?

[HighBoostin330]

really? hmmmm, maybe i will stop that order

thanks, aj, any comment?

Search my build thread. AJ posted about it. I remember talking to him at Bimmerfest. And they were scratching their head as to why the head continues to lift with ARP head studs and someone at ESS said let's just try the OEM head bolts and it worked.

[ritos530i]

I think this is happening to me because i am running ARP head studs. I wonder what's the procedure after replacing them with stock Studs. Do you replace gasket as well or just swap out the studs and torque it down to specs. The only thing that makes since to ARP studs being an issue is because of the all aluminum motor but don't quote me on this. A few guys that this has happen to said they just retorqued the head with the ARP studs to 75+lb instead of the normal 60-65lbs required with stock studs.
Let me know
Rito

[fmzip]

really? hmmmm, maybe i will stop that order

thanks, aj, any comment?

http://forum.e46fanatics.com/showthread.php?p=7277075&highlight=studs#post7277075

Hey Stu...see post #132 and your reply on #133 ;) It's an over 40 thing my friend!

[Mike Benvo]

Don't use ARP head studs... I would have the block rethreaded and thicker custom bolts made to keep it down.

My head used to lift and blow coolant all over caused by boost bleeding into the cooling jackets in the head and pressurizing the cooling system. :)

[steelgrey330ci]

I have the ARP head bolts on now but haven't noticed anything you guys are talking about.

[TxZHP04]

I have the ARP head bolts on now but haven't noticed anything you guys are talking about.

You're either lucky or more likely just not running enough boost for the head to lift.

[steelgrey330ci]

lol thx, I'm running 10.5 psi right now

[HighBoostin330]

lol thx, I'm running 10.5 psi right now

TS3 cars run at least 14PSI.

[330i ZHP]

arp bolts not being installed - so many tasks to get done

i need to order some oem sized 330 rotors for the wagon, finish dealing with the dmv tomorrow to get the sedan moved to MD from VA

and waiting on the order from ESS and the machine shop

[330i ZHP]

larger intake and exhaust valves ordered to keep the flow of the newly ported intake and exhaust runners in the head consistent

the head will flow so much better than OEM now

another set of cams are coming as well - so the wagon will now be TS2+

I have to pay for these but at least I am getting them for decent price - thanks Aj

[HighBoostin330]

larger intake and exhaust valves ordered to keep the flow of the newly ported intake and exhaust runners in the head consistent

the head will flow so much better than OEM now

another set of cams are coming as well - so the wagon will now be TS2+

I have to pay for these but at least I am getting them for decent price - thanks Aj

AJ is selling you larger intake and exhaust valves?

[330i ZHP]

nope

[HighBoostin330]

nope

Are you using Fedora valves?

Also, PM sent. :)

[steelgrey330ci]

well if any of you are looking for a great port and polished head with everything done pls let me know cause im selling mine. check the for sell section out but i can do something on the price if you are really interested.
look it up under my name

[330i ZHP]

Are you using Fedora valves?

Also, PM sent. :)

Ferrea valves

well if any of you are looking for a great port and polished head with everything done pls let me know cause im selling mine. check the for sell section out but i can do something on the price if you are really interested.
look it up under my name

why are you selling and you are a little late for my needs - good luck with the sale

[steelgrey330ci]

i need the tune to support the head which i dont have. The head flows very well but need more fuel for it

[ice330ci05]

i need the tune to support the head which i dont have. The head flows very well but need more fuel for it

so becouse of a TUNE you going to sell it and lose all that money??? i'm sure you can get someone to tune it for you in TO...

[steelgrey330ci]

well do you know anyone? here local cause its not something you can ask someone to make with out the car on a dyno to tune with.

[pei330ci]

well do you know anyone? here local cause its not something you can ask someone to make with out the car on a dyno to tune with.

Numerous times I've answered this question:

- Moristech Piggyback ECU + 2 X LC-1 = full fuel and spark control

- If you want your RPM limit changed, ESS and AA both can do this.

- The most elegant solution while maintaining full stock features is using a Pectel SQ-6 as a piggyback. As an example, this is how Apex Speed Technology is tuning Porsche 997s which are a LOT more tricky than BMW DMEs.

For tuning, there are LOTs of pros that you can fly in and have everything sorted in 1 to 2 days. Ed Senf, Neel Vasavada, and Rob May to name a few.

I keep telling people to get off the forums looking for advice and go to race tracks. This is where the real answers are.

Steelgrey330ci, I understand you are frustrated, but you've got some great resources in TO. Mike Booker for example has been using a number of different ECMs on his race car. I believe he's now using Motec which means he's probably in contact with a very good tuner. Markus Glarner...man I wish I lived in the same city as him...another great resource. I know Tony D. (E.A.T.) does a lot of custom tuning, but he's currently tied up for the next 5-6 weeks with a client.

My experience with doing projects, is to focus on building relationships with people that are doing the things you want to do. This is probably the best advice I can offer....

[330i ZHP]

assembled the rods, pistons, pins, clips and rings tonight - have to order new rod bearings and possibly new main bearings....$$$$$

[fmzip]

no need to turn the crank I hope??

[330i ZHP]

fran pm me with the question

[330i ZHP]

but no it was perfect

[HighBoostin330]

assembled the rods, pistons, pins, clips and rings tonight - have to order new rod bearings and possibly new main bearings....$$$$$

I remember AJ telling me that it was imperative that you reuse your rod bearings and main bearing. Disassemble them label them and re-install them exactly as removed. :dunno: I was just told that, so just FYI.

[330i ZHP]

well, that was the original idea - but there was enough wear on the bearing surfaces on the rod and main bearings (only a few) that the machine shop clean and polished the surfaces and prepped all the surfaces for new bearings....not to mention they didnt label the main bearings

I know the main bearings are standard size and green marked and the rods are standard and blue and red marked

So, new in this case is best

[pei330ci]

well, that was the original idea - but there was enough wear on the bearing surfaces on the rod and main bearings (only a few) that the machine shop clean and polished the surfaces and prepped all the surfaces for new bearings....not to mention they didnt label the main bearings

I know the main bearings are standard size and green marked and the rods are standard and blue and red marked

So, new in this case is best


Stuart,

I'm not sure if you read about my "bearing experience", but it was not good. I ordered OEM bearings from a well known vendor, and recieved something that looked different from what I had removed from the engine. When I asked the vendor what was up, I was told they were "OEM spec". Upon installation, I had huge clearance issues with both the crank and rod bearings.

I personally recommend buying your bearings directly from a dealer, (OEM makes them to a very high spec) and then check the clearances on EVERY journal upon installation.

Great build so far.

Regards,

Adam