BlueBug's 2004 Daily and Track Build

[BlueBug]

2004 6MT Sedan
Silver Grey w/ Black Interior
Mileage as of April 2017: 140,500 miles


Thought it would be wise to start a thread to plan and keep track of maintenance, repairs and upgrades.

Got this car in July 2016. Heard that it was in a minor accident: the car had hit a bad pothole and blew a the passenger side curtail airbag, the passenger rear tire had a big goose egg and the battery cable had blown. The previous owner wanted rid of the car and we bought it for a ridiculously low price ($1,700) thinking it would have a salvage title and not fully sure of how much damage we would find.
So towed the car home and repaired the battery cable and air bag. Replaced the two rear tires (no wheel damage) and replaced the rear shocks. Swapped out the street brake pads for track pads, did fluid flushes and changed oil.

The car was drivable and we decided to take it for a track day. Trailered it to Summit Point Shenandoah. The first time I drove this car was on track. It felt good, solid and willing, it handled seven 25 min sessions with zero issues.

It does need suspension upgrades and a diff.

http://i1113.photobucket.com/albums/k501/iVari/zhp%20in%20trailer.jpg (http://s1113.photobucket.com/user/iVari/media/zhp%20in%20trailer.jpg.html)

http://i1113.photobucket.com/albums/k501/iVari/zhp%20on%20karussel.jpg (http://s1113.photobucket.com/user/iVari/media/zhp%20on%20karussel.jpg.html)

http://i1113.photobucket.com/albums/k501/iVari/ZHP%207%20sml_1.jpg (http://s1113.photobucket.com/user/iVari/media/ZHP%207%20sml_1.jpg.html)

Now that the car proved itself it was time to redo the cooling system.
It's next outing was to Dominion Raceway which was still a construction zone and bumpy and rough.

http://i1113.photobucket.com/albums/k501/iVari/ZHP%20DR%201.jpg (http://s1113.photobucket.com/user/iVari/media/ZHP%20DR%201.jpg.html)

http://i1113.photobucket.com/albums/k501/iVari/ZHP%20DR%2021.jpg (http://s1113.photobucket.com/user/iVari/media/ZHP%20DR%2021.jpg.html)

Planned work for 2017:

Install a 3.64 diff - Done
Suspension upgrade - Done
Subframe reinforcement - Done
17" Apex wheels - Done
Rtab pocket reinforcement
Strut tower reinforcement
Engine mounts
Trans mounts

Planned work for 2018:

Bolt in roll bar, harness bar
6 point harness'
Fixed seats


Completed work:

7/16: All fluids changed
7/16: Airbag repair
7/16: Battery cable repair
7/16: Cooling system refreshed
4/7/17: All weather floor mats
4/7/17: New key
4/14/17: Control arm bushings
4/14/17: CDV Delete
5/4/17: Race Wheel Studs and Bolts installed
5/4/17: New front rotors
5/4/17: Front Sway Bar Links replaced
5/4/17: Front Hawk HT-10 track pads (replacing Hawk HP+ that suffered brake fade)
6/3/17: Subframe reinforcement
6/3/17: Poly subframe rear and front bushings
6/3/17: Poly diff rear and front bushings
6/3/17: Poly front sway bar bushings
6/3/17: Rear trailing arm bearing kit from BW
6/3/17: Installed 3.64 diff
6/3/17: Diff fluid - Redline 75W140 gear oil
6/3/17: Sway bar links
6/3/17: ISC N1 street coil over kit
6/3/17: New tie rods
6/3/17: Alignment
6/5/17: Stainless steel brake line kit
6/5/17: Brake fluid flush - Motul 600



The cars main job is a daily driver that will do a few track weekends. I'll edit and add to this as things come up and are needed.

[ZHPizza]

Man you stole that car! Well done.

Here's a 3.46 diff for sale. Just needs some LSD guts.

http://forum.e46fanatics.com/showthread.php?t=1125844

[Vas]

Subscribed

[BlueBug]

Man you stole that car! Well done.

Here's a 3.46 diff for sale. Just needs some LSD guts.

http://forum.e46fanatics.com/showthread.php?t=1125844

Yes, it was a steal and we'll probably never get a great car like this one for that price again. My husband intended to fix her up and resell or daily drive her himself. He didn't drive her much at all and pretty much parked her over winter, but I fell in love and can't see letting her go. It's too good a car with lots of potential to be in the family for years to come. So now I drive her to work etc and he has an e36 :)

https://uploads.tapatalk-cdn.com/20170406/21f2c0ac3cc45767360f652766781ec4.jpg

Thank you for the link to the diff. I have already bought the one from the white zhp part out car listed on here.
Really looking forward to feeling the difference. Maybe we'll upgrade to a LSD in the future. We even have a m3 diff and subframe, just missing the rest of the back end parts to make it work in the zhp.


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[BMWCurves]

I love seeing this kind of thing where a potentially scrapped car is resurrected by an enthusiast. Best possible outcome.

[derbo]

Great price!

Welcome. I'm looking forward to your progress. :)

[///Mvious]

Nice pickup! Looking forward to hearing about the track events and progress on the car

[Audi 0000]

Car looks great! I really enjoy the on track pics. 👍👍

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[BlueBug]

Now that I've been driving the car for a few weeks I'm noticing lots of little things.

The passenger side mirror would get stuck in the down position every time reverse was engaged. The side mirror switch does not work.
I took the switch out to check the connection and it was not loose. So will need a new one.
I did hook up the scanner and was only able to make the passenger side mirror adjust, the driver side mirror does not adjust.
My husband will have to diag this further for me.
Interestingly, the passenger side mirror now goes back to it's position after shifting out of reverse and seems to have fixed it self :dunno

http://i1113.photobucket.com/albums/k501/iVari/IMG_9191.jpg (http://s1113.photobucket.com/user/iVari/media/IMG_9191.jpg.html)

http://i1113.photobucket.com/albums/k501/iVari/IMG_9183.jpg (http://s1113.photobucket.com/user/iVari/media/IMG_9183.jpg.html)

Also found a wet spot in the passenger footwell after a heavy rain. Will clear out the sunroof drains this weekend. No water in driver side or in the trunk.

Found an old key under the passenger seat. Looks like the previous owner tried to change the battery at some point and gave up. I'll attempt to repair the key as a spare.
The new key from the dealer is working great, so in no hurry to fix the damaged key and I still have the other original key that also has a bad battery. :)

http://i1113.photobucket.com/albums/k501/iVari/IMG_9200.jpg (http://s1113.photobucket.com/user/iVari/media/IMG_9200.jpg.html)

http://i1113.photobucket.com/albums/k501/iVari/IMG_9135.jpg (http://s1113.photobucket.com/user/iVari/media/IMG_9135.jpg.html)

And the liner on the A pillars was falling off so I did the quick fix of just removing the fabric.

http://i1113.photobucket.com/albums/k501/iVari/IMG_9199.jpg (http://s1113.photobucket.com/user/iVari/media/IMG_9199.jpg.html)


The shadow trim on the passenger side has broken clips and doesn't sit right. Will need a new one.
The paint needs some TLC and has many swirls and scratches.
Also have a small chip in the windshield.

[anandoc]

I did hook up the scanner and was only able to make the passenger side mirror adjust, the driver side mirror does not adjust.


I think that may be the root of the problem. The driver's side mirror motor acts as the 'master' and the passenger side mirror motor acts as the 'slave'. So if the dirver's side mirror motor is broken, you would not be able to adjust the passenger side mirror using the switch - although the dip-down/dip-up at reverse might still work.

[ZHPizza]

I'm going to put my money on the ribbon cable going to the drivers mirror being the culprit. It tore in my last sedan and caused similar issues.

http://www.zhpmafia.com/forums/showthread.php?13611-Urgent-side-mirrors-not-working

Wet floor is likely vapor barrier on that door, but definitely check the sunroof drains. Most people will try to run a length of weed eater cord down the drain tube.

I bought my car with a dead key and eventually gave up on the idea of changing the battery. Dead key is dead. Good thing you've already got a new one!

And isn't it nice how the pillars look great without fabric? My favorite DIY to date is ripping off that old, faded, peeling fabric and saying "well...that looks just fine."

[anandoc]

I'm going to put my money on the ribbon cable going to the drivers mirror being the culprit. It tore in my last sedan and caused similar issues.



I had the same issue as well...but in my case the ribbon cable had magically burnt a small hole right in the middle. So weird!

[Sockethead]

Gawd I hate those mirrors... both of mine are torn

[ZHPizza]

I had the same issue as well...but in my case the ribbon cable had magically burnt a small hole right in the middle. So weird!

I attempted this fix on my sedan:

http://forum.e46fanatics.com/showthread.php?t=911005

it did not go well.

[Sockethead]

I tried that fix too and although all of the solder joints were sound, It still did not work

[ZHPizza]

I tried that fix too and although all of the solder joints were sound, It still did not work

Did you end up settling for manual mirrors too?

(roll down the window and push the glass to where you want it)

[Sockethead]

LOL, yep! That was a couple of years ago... haven't had to adjust them since :)

[BlueBug]

Many thanks for all the advice!!

I decided to pull the #57 fuse and rock manual mirrors :thumbup Didn't want to have the passenger mirror get stuck down again.

Got Ms. Zelda up on the lift for a few quick things.

http://i1113.photobucket.com/albums/k501/iVari/IMG_9220.jpg (http://s1113.photobucket.com/user/iVari/media/IMG_9220.jpg.html)

Got this nasty, horrible thing out:

http://i1113.photobucket.com/albums/k501/iVari/IMG_9219.jpg (http://s1113.photobucket.com/user/iVari/media/IMG_9219.jpg.html)

http://i1113.photobucket.com/albums/k501/iVari/IMG_9214.jpg (http://s1113.photobucket.com/user/iVari/media/IMG_9214.jpg.html)

What a difference it makes to have the CDV gone. Shifting is buttery smooth.. like it should be :roundel

Also replaced the control arm bushings.

http://i1113.photobucket.com/albums/k501/iVari/IMG_9205.jpg (http://s1113.photobucket.com/user/iVari/media/IMG_9205.jpg.html)

http://i1113.photobucket.com/albums/k501/iVari/IMG_9208.jpg (http://s1113.photobucket.com/user/iVari/media/IMG_9208.jpg.html)

http://i1113.photobucket.com/albums/k501/iVari/IMG_9210.jpg (http://s1113.photobucket.com/user/iVari/media/IMG_9210.jpg.html)

And it can't all be sunshine and unicorns :(
There is a lot of rust around the rear passenger area. No rust on the drivers side.

http://i1113.photobucket.com/albums/k501/iVari/IMG_9217.jpg (http://s1113.photobucket.com/user/iVari/media/IMG_9217.jpg.html)

http://i1113.photobucket.com/albums/k501/iVari/IMG_9216.jpg (http://s1113.photobucket.com/user/iVari/media/IMG_9216.jpg.html)

Next on the to-do list will be to install the diff and replace all bushings and mounts in the rear.
Might also try to get the trans and motor mounts done too.

[ELCID86]

Do at least the trans mounts! I too am a fan of no CDV though some say they can't tell a difference.

[BlueBug]

Do at least the trans mounts! I too am a fan of no CDV though some say they can't tell a difference.

Will do!

I find a difference without the CDV, it's not all jerky (especially going into 2nd gear) and I can feel the clutch engage better.

[san]

some say they can't tell a difference.

Yup I'm one of them, didn't really notice any difference...


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[BlueBug]

Took a visit out to Summit Point to see a friend and spotted a ZHP on track [emoji106]
I wonder if they are a mafia member..

https://uploads.tapatalk-cdn.com/20170416/5d2f31896cdc8181b771eca45b2efa18.jpg

https://uploads.tapatalk-cdn.com/20170416/5b415117ddf73528b0cf949d59a904ef.jpg



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[BlueBug]

That owner is not a mafia member, but he is on e46fanatics. Very nice guy who loves his zhp [emoji41]


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[Vas]

That owner is not a mafia member, but he is on e46fanatics. Very nice guy who loves his zhp [emoji41]


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Sounds like he needs to join

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[BlueBug]

https://uploads.tapatalk-cdn.com/20170422/736a1dabbe9440fa4ad361a404045e8b.jpg

The cars have been pampered and are ready for a day on Summit Point Jefferson tomorrow.
The older sister, e30, makes her first appearance out of winter hibernation.

ZHP is really a perfect track warrior!
Have her loaded up with a large canopy, 3 chairs, variety of tools, rags and fluids [emoji4]

https://uploads.tapatalk-cdn.com/20170422/fbb577c44e3ca4512333c19dc27bb85f.jpg


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[Vas]

How was the track in this rain we had in Virginia?

Saw this on Instagram

https://www.instagram.com/p/BTNc1QOAO7r/

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[BlueBug]

How was the track in this rain we had in Virginia?

Saw this on Instagram

https://www.instagram.com/p/BTNc1QOAO7r/

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The track was pretty good overall considering we did get steady rain. The extension had fresh sealant and was slick in some spots.
There were 3 turkeys [emoji884] running around on track, none hit thankfully.

We ran one 30 min session reverse track, that was fun!

The zhp was great, had lots of grip with the Michelin tires.

Very cool to have her photo posted by Bimmerworld [emoji4]

Going to save a screenshot of that post here:
https://uploads.tapatalk-cdn.com/20170423/0148b69483f09bbbad9aad335dc461ef.jpg


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[Lorenzo]

:thumbup

I am doing my first HPDE school in September. I assume it is an exhilarating experience.

[Sockethead]

It is.... as soon as you get done one, you'll want to do another and another....

[Lorenzo]

It is.... as soon as you get done one, you'll want to do another and another....

I have heard that it is addicting and have been warned it gets expensive with all the wear on the consumables - brakes, fluids, tires, etc.

[Sockethead]

I have heard that it is addicting and have been warned it gets expensive with all the wear on the consumables - brakes, fluids, tires, etc.


It depends on how much you get into it but...

https://uploads.tapatalk-cdn.com/20170423/a96dae3d2630661ce585d036852e4d03.jpg

[BlueBug]

:thumbup

I am doing my first HPDE school in September. I assume it is an exhilarating experience.

Yes, yes it is an amazing experience and very educational. It is highly addictive and worth every penny spent!!

Just make sure your car is in good health. Most important areas are brakes, tires, fresh fluids and cooling system.

There isn't much need for too many performance upgrades when starting out.. a set of track pads and upgraded brake fluid would be ideal.


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[Lorenzo]

Yes, yes it is an amazing experience and very educational. It is highly addictive and worth every penny spent!!

Just make sure your car is in good health. Most important areas are brakes, tires, fresh fluids and cooling system.

There isn't much need for too many performance upgrades when starting out.. a set of track pads and upgraded brake fluid would be ideal.


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Good advice thank you. I'm nervous to bring my ZHP it's got 150,000 miles and I'm still working to get it a bit more reliable and healthy. I was thinking of bringing my 428. I'm afraid to bring ZHP and run into an issue on the track and I can't drive it. I know the 428 is in perfect working order. But I have until September to sort out any remaining issues. I just need more time with the car to let it expose its issues.


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[Sockethead]

I have 143K and I just put a supercharger on it. BP has something like 250K and still tracks his car several times a year. These cars hold up well as long as they've been maintained.

No matter what car you take, the main thing you want to do is have fun. You don't need to push the car or yourself the first time you go out. Plus you'll have an instructor in the car helping you...

[az3579]

I have 143K and I just put a supercharger on it. BP has something like 250K and still tracks his car several times a year. These cars hold up well as long as they've been maintained.

No matter what car you take, the main thing you want to do is have fun. You don't need to push the car or yourself the first time you go out. Plus you'll have an instructor in the car helping you...
Just over 267k here. If your car is safe to drive on the street (as in, you have zero mechanical problems), then it is safe to drive on track.

You'll also find that folks at the track tend to carry around spare parts. You'd be surprised what people can provide at the drop of a hat... With that said, you should also carry spare parts. What, is up to you.



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[Lorenzo]

Ok cool. The only issue I may have on my ZHP is a small amount of leaking oil. But I've addressed the three major causes - oil filter housing gasket, oil pan gasket and the valve cover gasket. And I was leaking a little bit of power steering fluid after a fresh flush but today I replaced the gasket on the reservoir cap and so far it looks OK. So hopefully over the next several months of autocross and street driving and then by September everything will be completely sorted that needs to be sorted before HPDE. I'll also be getting the tech inspection in advance by a local shop here and hopefully that will come out clean.

I'm just trying to avoid any surprises. I'm a bit gun shy because when I took my ZHP to my first autocross event, the water pump failed on me - which I know is a normal item. But ever since then I've been a bit spooked. It helps to hear everyone's else going long past my mileage and still pushing their cars hard.

[az3579]

The water pump isn't the only thing you should do with the cooling system. Almost all of it has to get done.

I maintain my car fanatically so that I don't have any surprises on long trips or at the track. I'm glad I don't keep records of how much I spend on my car; I'd be scared to know.

[Lorenzo]

The water pump isn't the only thing you should do with the cooling system. Almost all of it has to get done.

I maintain my car fanatically so that I don't have any surprises on long trips or at the track. I'm glad I don't keep records of how much I spend on my car; I'd be scared to know.

Sorry correction. It was my Fuel Pump that failed at autocross. I've already done the complete coolant system overall.

[BlueBug]

Good advice thank you. I'm nervous to bring my ZHP it's got 150,000 miles and I'm still working to get it a bit more reliable and healthy. I was thinking of bringing my 428. I'm afraid to bring ZHP and run into an issue on the track and I can't drive it. I know the 428 is in perfect working order. But I have until September to sort out any remaining issues. I just need more time with the car to let it expose its issues.


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150k is nothing to worry about as others have mentioned.
Mine has 140k and feels strong.

Which event are you planning to do in September?


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[Lorenzo]

150k is nothing to worry about as others have mentioned.
Mine has 140k and feels strong.

Which event are you planning to do in September?


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NCC Sep 8, Summit Point, Shenandoah HPDE

https://www.motorsportreg.com/events/ncc-september-2017-summit-point-shenandoah-hpde-raceway-bmw-cca-national-082995

[BlueBug]

NCC Sep 8, Summit Point, Shenandoah HPDE

https://www.motorsportreg.com/events/ncc-september-2017-summit-point-shenandoah-hpde-raceway-bmw-cca-national-082995

Very cool, I'm planning to do that event also :)
Shenandoah was where I did my first track day and it's my favorite.



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[BlueBug]

Spent the weekend at Dominion Raceway... working, not driving. Wasn't ready for this heat this early in the season.

https://uploads.tapatalk-cdn.com/20170430/1f78e6ae24a509d5e1c48ddfbdea3302.jpg

Found a promotional card in the main building with a picture of my car on track! What a neat surprise :)

https://uploads.tapatalk-cdn.com/20170430/497ccb8d7a105aac42c847e9d3100594.jpg

https://uploads.tapatalk-cdn.com/20170430/bff2b49994049e019c8b74be85141a68.jpg




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[ELCID86]

Spent the weekend at Dominion Raceway... working, not driving. Wasn't ready for this heat this early in the season.

https://uploads.tapatalk-cdn.com/20170430/1f78e6ae24a509d5e1c48ddfbdea3302.jpg

Found a promotional card in the main building with a picture of my car on track! What a neat surprise :)

https://uploads.tapatalk-cdn.com/20170430/497ccb8d7a105aac42c847e9d3100594.jpg

https://uploads.tapatalk-cdn.com/20170430/bff2b49994049e019c8b74be85141a68.jpg




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Not far from me! Yesterday was a bit on the warm side.

[BlueBug]

And I scored a set of used Apex track wheels, 17 x 9, with Hoosier slicks mounted [emoji2]

The car doesn't need slicks just yet, but they should be a fun experience!

https://uploads.tapatalk-cdn.com/20170430/2db4440eca8426f27dea5a595ac75462.jpg


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[Audi 0000]

And I scored a set of used Apex track wheels, 17 x 9, with Hoosier slicks mounted [emoji2]

The car doesn't need slicks just yet, but they should be a fun experience!

https://uploads.tapatalk-cdn.com/20170430/2db4440eca8426f27dea5a595ac75462.jpg


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Awesome! Much want, love Apex wheels :)

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[san]

Will the 17x9 fit without fender rolling?


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[BlueBug]

Will the 17x9 fit without fender rolling?


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The fenders will have to be rolled :)

[BlueBug]

Some goodies arrived today:

Wheel studs and bolts [emoji2]

https://uploads.tapatalk-cdn.com/20170503/d99b19b033816a8e5fb83cd363590225.jpg

And a 3.46 differential

https://uploads.tapatalk-cdn.com/20170503/cf1252341e9e33084650811442383716.jpg




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[Sockethead]

Sweet! The diff will make a huge difference coming out of the tight corners. I really like having studs too

[ZHPizza]

Lol great pic of the diff!

Are there benefits to the studs outside of the ease of mounting/dismounting wheels?

[BlueBug]

Lol great pic of the diff!

Are there benefits to the studs outside of the ease of mounting/dismounting wheels?

I know.. should get a prize for the detailed diff photo [emoji851]
It was packed so well and in a sea of peanut foam that I gave up lol

The studs are stronger and wheel changes will be a lot easier. They'll also help with adding wheel spacers. We are putting 5mil spacers on the rear to prevent rubbing on the inside and rolling the fenders to prevent rubbing on the outside.


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[BMWCurves]

LSD or just the 3.46 ratio? Nice pick up either way!

[BlueBug]

LSD or just the 3.46 ratio? Nice pick up either way!

Just a 3.46 out of an auto zhp. I do have a M3 diff that would be awesome in the car, but it would be too much work and too many other parts needed to make it work.

I think the 3.46 will be a nice improvement and plenty for what the car needs to do.


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[Vas]

Just a 3.46 out of an auto zhp. I do have a M3 diff that would be awesome in the car, but it would be too much work and too many other parts needed to make it work.

I think the 3.46 will be a nice improvement and plenty for what the car needs to do.


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The auto zhp cars have a 3.64

Check the label on the diff.

[BlueBug]

The auto zhp cars have a 3.64

Check the label on the diff.

Thanks Vas, I thought is was a .46... learn something new everyday :)

Got the studs on today and fresh front rotors, also replaced the sway bar links and rolled the rear fenders.

Hoping to run at Dominion on Saturday with TrackDaze.

Next on the list will be the subframe reinforcement and diff install.

Old:
https://uploads.tapatalk-cdn.com/20170505/09cc971b8b9192a1b756dbb5e215ac15.jpg

New:
https://uploads.tapatalk-cdn.com/20170505/1975d72edfd1014c6ac97e2920ae3ed6.jpg

Worn sway bar link:
https://uploads.tapatalk-cdn.com/20170505/f0fc86b84e74b79fc694a4dc790ff199.jpg

Fender rolling:
https://uploads.tapatalk-cdn.com/20170505/43be88486a8fcbb7c36f30851129423a.jpg


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[johnrando]

:like

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[derbo]

Some goodies arrived today:

Wheel studs and bolts [emoji2]

https://uploads.tapatalk-cdn.com/20170503/d99b19b033816a8e5fb83cd363590225.jpg

And a 3.46 differential

https://uploads.tapatalk-cdn.com/20170503/cf1252341e9e33084650811442383716.jpg




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Those look like Bimmerworld studs :)

[BlueBug]

Those look like Bimmerworld studs :)

Good eye!!! They are BW studs :)


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[derbo]

Good eye!!! They are BW studs :)


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Only reason I know is because I have the same studs in 82mm with the dry loctite


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[BlueBug]

https://uploads.tapatalk-cdn.com/20170525/a961f3f94714f3ca8d5ac724b23a538d.jpg

https://uploads.tapatalk-cdn.com/20170525/4f95db260388fe4f453ae10e740a7be2.jpg

Lots of new parts for Ms. Zelda, aka Clunky.

We went to VIR this past weekend for Hyperfest, I drove the ZHP down for paddock duties. On the trip down, 200+ miles, there was a lot of clunking noise coming from the front end. Took a quick look and the shock mounts were bad. Didn't have time to turn around. The car felt sloppy and loose and was a handful on uneven surface.

All that was the perfect excuse to plan a suspension refresh, subframe reinforcement, diff install, new tierods, new bushings etc.

Ordered parts from Bimmerworld yesterday and everything arrived today!!
After emailing with Bimmerworld about recommendations for the suspension we decided to go with the ISC coilover package. Apparently most of the BW staff have this installed in their personal cars.

Hoping to get everything done over the weekend. I can't wait to feel the improvements!!

Parts list:

Rear subframe front bushings.
Rear subframe rear bushings.
Diff front bushings.
Diff rear bushings.
Subframe reinforcement kit.
Rear trailing arm bearing kit.
ISC coilover kit.
Tie rods.

After this will plan for engine and trans mounts.


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[///Mvious]

Getting after it...nice progress! Should be a very nice difference for the next track event

[Sockethead]

Nice to you see your car getting a lot of love. Especially one that was destined for the boneyard.
Should be pretty damn solid after all the upgrades

[BlueBug]

Getting after it...nice progress! Should be a very nice difference for the next track event

Yes, lots of work needed to make her perfect! Just trying to knock a few things out at a time.
Next track event can't come soon enough :)



Nice to you see your car getting a lot of love. Especially one that was destined for the boneyard.
Should be pretty damn solid after all the upgrades

Thank you! This car is a keeper. Every time we do something we find so much more that needs work. It's going to be a never ending list I think.

The back end is out!!

https://uploads.tapatalk-cdn.com/20170526/3e959b74031e46976499bd1128dab1f8.jpg

https://uploads.tapatalk-cdn.com/20170526/e81451914690b5b734a1c89402144aee.jpg

The first bushing we removed was in bad shape.
Photos below are the rear diff bushing. All others are looking the same. At least the replacement polly bushings will hold up better.

https://uploads.tapatalk-cdn.com/20170526/5ebc43a22e9fe55af257715dc5ca6534.jpg

https://uploads.tapatalk-cdn.com/20170526/31f43d8154463de97f0a76626dda6c26.jpg


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[BlueBug]

While we have everything out of the car we are going to add some welds to the Rear Trailing Arm pocket.
This bad accident (video link below) happened at VIR last weekend due to a serious failure. I was spotting at that turn when the accident happened and know the driver, thankfully he walked away with no serious injuries.
Granted the car is a fully built race car that has taken a beating for a few years.. but it's enough to make me want to do a little something for peace of mind.

E46 Rear Trailing Arm Pocket Failure (https://www.youtube.com/watch?v=J4zPECASIrs)

[san]

Wow, is that the subframe/racp completely getting ripped off?


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[Sockethead]

That's typical for that bushing. Every rear diff bushing I've seen has been cracked. Not a very good design the way it twists on several different planes
The poly should take some of the slop out of the drivetrain when your shifting hard

[ZHPizza]

E46 Rear Trailing Arm Pocket Failure (https://www.youtube.com/watch?v=J4zPECASIrs)

Holy shit.

[Vas]

Any cracks visible?

[nextelbuddy]

While we have everything out of the car we are going to add some welds to the Rear Trailing Arm pocket.
This bad accident (video link below) happened at VIR last weekend due to a serious failure. I was spotting at that turn when the accident happened and know the driver, thankfully he walked away with no serious injuries.
Granted the car is a fully built race car that has taken a beating for a few years.. but it's enough to make me want to do a little something for peace of mind.

E46 Rear Trailing Arm Pocket Failure (https://www.youtube.com/watch?v=J4zPECASIrs)

well that was unexpected.. how scary is that.. on the flipside, its good to see how well that cage protected the driver. didnt even flex or flinch.

[BlueBug]

Wow, is that the subframe/racp completely getting ripped off?


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The rcap ripped out.
These photos are from the race car in the video:

https://uploads.tapatalk-cdn.com/20170526/51c0c0ecea9fe3651d97bb3d170d077d.jpg

https://uploads.tapatalk-cdn.com/20170526/f7ea5aee9189268313bb14a97d6faa4b.jpg


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[BlueBug]

Any cracks visible?

No cracks on the zhp that I can see. Will clean it up and take a closer look over the weekend.
No visible cracks around the subframe mounts either.

https://uploads.tapatalk-cdn.com/20170526/7d15942d3cbb9771c00a3afac4dacc33.jpg


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[slater]

well that was unexpected.. how scary is that.. on the flipside, its good to see how well that cage protected the driver. didnt even flex or flinch.

dude... ouch. ;)



The rcap ripped out.
These photos are from the race car in the video:

https://uploads.tapatalk-cdn.com/20170526/51c0c0ecea9fe3651d97bb3d170d077d.jpg

https://uploads.tapatalk-cdn.com/20170526/f7ea5aee9189268313bb14a97d6faa4b.jpg

do you know what kind of RTAB the person was using?

it is very obvious (to me) that limiters and poly bushings will put undue strain on the RTAB pockets under extreme articulation. spherical RTABs should prevent, or at least lessen, the chances of this happening - and in this case, it was catastrophic.

you might want to considering placing a few rivets in the RTAB pocket alongside the factory spot welds? (i might do this as well now after seeing this.)



No cracks on the zhp that I can see. Will clean it up and take a closer look over the weekend.
No visible cracks around the subframe mounts either.

definitely check the 'kink' on the rear floor, inboard of the left rear subframe mounting point - that is where they crack first. the crack will be very small (under 30mm in length), and it may be covered in road crud, so degreasing the area to inspect is a good idea.

[Sockethead]

I knew the e36 is vulnerable at the trailing arm mount pocket and there is a reinforcement kit for that but I was unaware the e46 has the same issue.
I'm always looking through the e46 spec catalogue on different sites (VAC Bimmerworld, etc ) but I have yet to see a reinforcement kit for the e46...

[Sockethead]

BTW, if you are going to track this car long term there is a reinforcement kit for the rear swaybar mounts. Might want to consider that as long as you have the subframe out

[BlueBug]

Found a decent sized crack in the front passenger side mount area. Didn't find any other cracks.

Still have to clean the rtab pockets after the subframe reinforcements are done.

https://uploads.tapatalk-cdn.com/20170527/31980e1eeb136b405c7bde52fd5dc452.jpg


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[Vas]

Found a decent sized crack in the front passenger side mount area. Didn't find any other cracks.

Still have to clean the rtab pockets after the subframe reinforcements are done.

https://uploads.tapatalk-cdn.com/20170527/31980e1eeb136b405c7bde52fd5dc452.jpg


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Is this where the subframe bolts or where the rtab goes ?

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[BlueBug]

Is this where the subframe bolts or where the rtab goes ?

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This is where the subframe bolts.

We haven't cleaned the rtab pockets yet, but I'd be surprised if we find anything there.


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[BlueBug]

Got the car out on track with BMWCCA to see how the latest upgrades felt and the car was solid and felt nicely neutral. It was a huge difference from the stock suspension.
Actually felt like driving a totally different car... in a really good way [emoji4]

I was very lucky to have Bobby, Audi 0000, as my instructor for the whole weekend. I learned a lot from him and had a really great time on track. He was able to get my speed up and helped me with looking further down track.

The weather was a little on the hot side. We noticed the water temp jump up to 220f at one point, Bobby put the heat on full blast and temps dropped quickly. That was the only small 'issue' all weekend. The car felt happy and willing.

The only ick thing was that we ran over a squirrel at speed, the poor guy ran out so quickly that nothing could be done. It was a clean hit and he probably died instantly. He did get revenge by knocking out one of the fog light cover/frame things. And someone actually found it and returned it to me!

We still have to replace the trans and engine mounts. Hopefully will get around to that in the next few weeks.

Here is a video of two laps on the Jefferson circuit:

https://www.youtube.com/watch?v=_15CfW6d6ys&feature=youtu.be

Some snap shots:

https://uploads.tapatalk-cdn.com/20170612/27364c4d1f69d22276a079bb8de3ed9d.jpg

After track inspection.. nothing broken or leaking :)

https://uploads.tapatalk-cdn.com/20170612/bcd54e4eb930187c7e13268d51ac56bc.jpg

Stock wheels back on:

https://uploads.tapatalk-cdn.com/20170612/e9bb46d8eed4244d28e3a33234809565.jpg

So much dirt from skidpad sessions:

https://uploads.tapatalk-cdn.com/20170612/2b666de4d70441085f489b2a7307e459.jpg

Waiting for skidpad behind Bobby's wife :)

https://uploads.tapatalk-cdn.com/20170612/43a2326788bdf2c5b0d343bc1944ad53.jpg


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[BMWCurves]

Very cool :thumbsup

[Vas]

Open diff on the skidpad is something interesting to say the least.

[Johnmadd]

Very cool. I've met Bobby a couple times, I'm sure you guys had fun and he was able to simplify the learning experience.

[BlueBug]

Very cool. I've met Bobby a couple times, I'm sure you guys had fun and he was able to simplify the learning experience.



He sure did simplify learning and went a step further by demonstrating everything by example in his car. It was a very fun and educational weekend :)


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