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Trackculture BMW E46 M3 with S85 V10 M5 Engine


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#1 PhilMorrison

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Posted 18 June 2010 - 03:21 PM

The story starts with seeing this car advertised on ebay. You may well recognise the picture, as the company I bought it off had so many requests to buy it, that they've used the same picture many times in adverts on ebay and pistonheads to sell replicas.

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It had Terrible Tein coilovers fitted, but had genuine CSL wheels, some big CAA front brakes, and a catalogue of genuine ACS parts.

My previous cars have mostly been Powerful and Japanese. I'd been out in a friends recently acquired E36 M3 and kind of dug it, so I thought I'd test drive this E46 to see if it was for me. After a long journey down, and a quick test drive. I'd put a deposit down on the car, and was on my way back preparing to sell everything I owned to purchase this car.

Much like pretty much every car I've bought in the past 10 years, my intentions were to not go nuts modifying it... That lasted all of about two weeks.
I wanted to run some left over partworn Federal track tyres on the M3 as they are absolutely awesom grippy tyres, but we only had them in 18" so they were no good on the CSL wheels. So I bought some 18" BBS of a friend of mine, and rolled the lip of the arches for a little more clearance (scary moment on such an expensive car). At the same time I fitted a Seibon carbon fibre bootlid, and some smoked LED rear lights and some black front indicators.

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I fitted a Stoptech rear big brake kit, that balances out the big fronts very well.

Then I took my first trip to the Nurburgring B) Pretty much everyone here is well aware of the feeling you get the first time you go there. It changed me, and I completely forgot about my idea's of not modifying the car.

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Back to the daily driver grind, I put the CSL wheels back on, and colour coded the grill, rear diffuser, and the front splitter. I also got rid of the stupid stansion things on the ACS front splitter.

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I swapped out the Tein coilovers for a set of the awesome HSD's.

Obviously, I have a lot of love for the CSL, and in search of a bit more power I bought a cheap(ish) ebay carbon airbox. It wasn't exactly a direct fit, but after a morning of bonding metal outlets into the carbon for the various pipes like idle control, it fitted and looked like this:

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I ran it in limp alpha N mode, then visited AL Tuning to have a proper alpha N map.


I didn't like the air filter set up, so moved the filter just behind the front bumper, away from all the heat.

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After a quick clean I took these shots

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We got some new wheels in stock, so I had to give them a go. Rota Grid 18x10 ET20 all round

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We had a blast around Oulton Park. Here's a video of Me in the E46 and my friends Paz and Jay in their E36 M3's

http://www.vimeo.com/3224498

The car was a little dirty by the end of that session ;)

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I bought some Kelleners sports cams, had it remapped again and it made 369bhp, then after a long search on German ebay, I managed to get these little beauties delivered.
18x10 and 8.5 AC Schnitzer 3 peice wheels. Most modern BMW owners really don't get it, but I think these wheels look just about perfect on the E46 M3.

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I bought an Eissenmann back box to mate up to a Supersprint mid section and the 100cell cats I already had fitted.

I had the cars paint corrected

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I went to the Nurburgring again a couple weeks ago

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And last week I did this:

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Why you ask? Well there was nothing wrong with the engine, it still ran superbly, sounded superb, and was generally awesome and fast, but I've been hatching a plan for the past 6 months, that will explain why this is in my workshop:
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and this is also sitting there:
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For those of you that just see lumps of metal, it's an E60 M5 5.0 V10 engine, and an E92 M3 6 speed manual gearbox. That plus my M3 should equal awesome :D
They fit together like this:
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I'm in the process of finding the time to fit the engine into the bay as it's going to require a crossmember modification, engine mounts fabricating, gearbox mounts, and manifolds, plus a whole load of other stuff.
I've also placed the order for a Pectel SQ6M ECU with Cosworth engine loom, and Cosworth Dash 2. It's about the most money I've ever spent in my life for those three things, but I've messed about with random ECU's and engine looms in the past, and this time I figured 'no thanks, let's not fuck about' So the best of the best it is, and I'll put the new house purchase on hold :D haha :D!

I'll update this thread as soon as I pull my finger out and get back on it. For now this is my daily driver:

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Trackculture/KMS/Dynotorque/Cosworth/Pectel V10 E46 M3

#2 Hannah

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Posted 18 June 2010 - 03:44 PM

I had bad thoughts when reading this, looks farking beautiful and bet it sounds amazing.

Oh and that looks mighty low on the karussel and where's your helmet?

#3 Simon

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Posted 18 June 2010 - 04:22 PM

Wow, this is going to be a whole new kind of awesome once finished. Didn't you get just a little bit worried pulling a perfectly good M3 apart?

Whats the news on the Nissan? Any chance of a few more pics and few details B)

#4 Nigel

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Posted 18 June 2010 - 04:48 PM

How much more does the V10 weigh over the 6 pot?

And is that a president? :D

#5 PhilMorrison

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Posted 18 June 2010 - 11:12 PM

Hi Hannah: Yeah it's a bit to low around there :D, regarding the helmet; sometimes I wear it sometimes I don't.Although the more I go there the more I think I should always wear it.
Trackculture/KMS/Dynotorque/Cosworth/Pectel V10 E46 M3

#6 PhilMorrison

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Posted 18 June 2010 - 11:16 PM

Hi Simon: Yes I did. it feels completely nuts to do this to a perfectly good car. I'm sure it'll all start to make sense soon though :D.
It's a President. 4.4v8 and a full hydraulic lowrider with a 4pump system. It's my going slow car :D
Trackculture/KMS/Dynotorque/Cosworth/Pectel V10 E46 M3

#7 PhilMorrison

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Posted 18 June 2010 - 11:20 PM

hi Nigel: Turns out it's 50kg heavier on my Intercomp scales, which is not what I was expecting when doing the calculations using BMW's given weights, but I'm still okay with the extra weight for the sake of 560 na v10 horses :D
Trackculture/KMS/Dynotorque/Cosworth/Pectel V10 E46 M3

#8 Gassyman

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Posted 19 June 2010 - 05:44 PM

That is one awesome M3! Going to be an animal when done.

#9 PhilMorrison

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Posted 24 September 2010 - 10:07 AM

Some progress! :) Check out the blog here: http://www.trackcult...rsion-progress/

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It’s been a few months since anyone last heard about this project. We were set back by an incredibly challenging season of drifting, which as of this weekend will be coming to a close.
However there’s been a lot of work going on in the back ground. First and foremost the best decision I made was to enlist the help of our next door neighbours Dynotorque, who are responsible for 90% of the LS V8 Engine conversions in to RX7′s and BMW’s in the UK.
Craig the owner of Dynotorque is a dab hand at engine conversions, and considering the scale of this particular swap, and my distinct lack of ramp time available in our workshops, it just made sense to enlist their services.
I also decided to go with a Pectel ECU system put together by Cosworth and KMS Racing Engines in Holland. These guys have plenty of race experience with the V10, and are one of the few companies to have made the V10 work in another car. Their expertise has been invaluable so far, and we haven’t even received the ECU and loom yet.
So here we start with the pictures of the fabrication. Please excuse the logo’s on each picture. It’s part of the arrangement with the companies that have played a part in building this car. Without them it wouldn’t be happening!
The car is pushed round to our next door neighbours Dynotorque, and sat in what will be it’s home for the next month, and the pallet of V10!
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Ready to take a run up and smash the engine in the hole!
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Okay, so a bit more ‘a little bit’ more finesse is required
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Craig supports the engine on the inner wings so we can have a look at the minefield of fitment issues underneath.Posted Image
The engines pushed back right to the bulkhead to see what sort of space we’re going to need up top too.
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With the engine position measured, the gearbox was held in position, and Craig made the gearbox mount using the E92 M3 gearbox mount shaved down, strengthened with plating, and mounted up to the car body using a milled block of alloy to perfectly fit the uneven mounting surface, and level up the mount beautifully.
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Then with the gearbox mount in place, he turned his attention to the front crossmember. This had to be scalloped significantly to accept the sump from the V10. It was strengthened inside with 1/4 steel bar, and plated together.
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In this shot you can also see the temporary support used to help make small adjustments to the positioning of the engine.
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Then came the time for engine mounts. This was really tight, as we wanted to keep the standard headers on the engine because they are a bit of a masterpiece. Well done BMW!
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Some stainless steel plate was cut to mount to the block, and some heavy duty LS engine mounts used. We don’t want this engine to move as there’s about 5mm clearance between headers and chassis rails, but we also don’t want excessive vibration. Here you can see it just tacked together.
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Now the drivers side (right side for us in the UK) was a very tight squeeze. Not only were the headers an issue, but you can also see here the first view of the steering rack we’ve swapped to for further clearance on the front part of the sump where the cam chain sticks out. The BMW rack is very thick, so we’ve gained a huge amount of room without effecting rack positioning.
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Now this is a massive deal! It’s a bit of a shame to only give it one picture, as the work that has gone into solving the steering column/header clearance issue is immense! Most people would give up when they see an issue of this scale, but not Dynotorque!
What you see in this picture is a steering column modified to have an extra universal joint. One of the original joints was moved into the car, then a straight shaft is supported by a modified AlfaRomeo Wheel bearing, which goes to another UJ, which passes through a perfectly scalloped section of the chassis rail, which has been reinforced to retain the same strength. It then hits the Mazda steering rack which happens to be the same ratio as a CSL rack, but with more lock… PERFECTION!
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After these mamouth tasks were taken on, we finally stepped back, looked at the car, and new that this was actually going to happen! We felt a congratulatory fitment of the plenums was in order. Checking for Bonnet clearance. There is loads!!! Awesome!
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After we had a custom propshaft made (E92M3 and E46M3 rear), it was time for the exhaust work. The standard headers had the Cats chopped off, and new stainless flanges welded on. Things are tight, and we tried to ensure the exhaust cleared the external engine oil pumps, and suspension bushes which are prone to melting, but also to make sure ground clearance was at a maximum, as I like my cars low!
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Craig has become a dab hand at TIG welding in recent years, and I’m really pleased with the work he’s done mating the V10 engine to the Supersprint mid section leading to Eisenmann backbox.
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And that’s where we’re at right now! Most of the big fabrication work is complete. Craig from Dynotorque has worked his ass off on this car for a month straight, and I’m sure you’ll agree the work is brilliant.
He has a lot more little jobs to take on, like repositioning and piping the ABS unit, fitting the M5 radiator, and all of the hose work to get this to run, so we’ve still got a couple more weeks work here. Then we’re just waiting on the Pectel SQ6M12 ECU, Cosworth motorsports loom, Cosworth Omega Dash , and an extremely trick Mechanical throttle linkage, all from KMS Racing Engines, which will allow us to run a normal cable throttle on the 10 Independent throttle bodies.
Watch this space for the next installment of the Trackculture.com E46 M3 V10 Conversion!
Trackculture/KMS/Dynotorque/Cosworth/Pectel V10 E46 M3

#10 Blackadder

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Posted 24 September 2010 - 10:14 PM

Epic, seriously need a video of the sound as soon as you get that engine fit! Failing that give me a date and i'll take a trip up to do some convenient timed shopping from driftworks :rolleyes:
Dan

Traction control???? Wash your mouth out with soap!!!!


#11 Mattfduk

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Posted 29 September 2010 - 08:17 PM

Got to love the work going into this.

I have seen the work Craig has done on a number of FD's with V8's and it looks factory so your M3 should end up looking like the love child BMW didnt have the balls to make

#12 PhilMorrison

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Posted 29 September 2010 - 09:47 PM

I'm super excited. I should be receiving the Mechanical throttle linkage, Pectel Management, Cosworth loom, and Cosworth dash tomorrow. Pictures will of course be up here asap B)
Trackculture/KMS/Dynotorque/Cosworth/Pectel V10 E46 M3

#13 Marcar

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Posted 30 September 2010 - 05:40 PM

I wanna hear it!! ....so much!
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John Marcar - E36 Geek, Trackday Organiser, Writer & the TC blogger bloke

TWITTER: @JohnMarcar

#14 PhilMorrison

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Posted 30 September 2010 - 08:28 PM

The most expensive box of parts in the world was delivered from KMS Engines today! B) Pectel SQ6M12 ECU, Cosworth motorsport loom and all new sensors. Cosworth dash, oil relocation plate, and the mechanical geared throttle linkage. It's amazingly comprehensive, and I can't wait to get stuck into plugging in the loom and mounting the dash..
Looking at it, it really does give me a very positive feeling that this will actually be completed this year B) I'll put some pics up of the new parts tomorrow.
Trackculture/KMS/Dynotorque/Cosworth/Pectel V10 E46 M3

#15 Blackadder

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Posted 01 October 2010 - 11:40 AM

Is this going to have a cage/any reinforcements in or just as daily as any other m3. And are you going to upgrade the brakes ? Other than taking the old engine out and putting a great big v10 lump in, what other plans do you have ?
Dan

Traction control???? Wash your mouth out with soap!!!!


#16 PhilMorrison

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Posted 01 October 2010 - 03:59 PM

I really don't want a cage, but I do intend on doing 200+mph in it, so I really should! If I do, I'll try and keep it 'covert'..
It's already got 6pot 360mm front brakes with Pagid blues, and 4pot 360mm rears. It's also got HSD coilovers, H&R anti roll bars, powerflex bushes CSL seats and steering wheel. I've got some new lips and polished centres for the wheels, that I'm about to build up that will give it a 11.5" wide rear for the 285/30/18 Federal RSR track tyres. It's basically ready to go once the engines done.
Trackculture/KMS/Dynotorque/Cosworth/Pectel V10 E46 M3

#17 PhilMorrison

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Posted 01 October 2010 - 04:11 PM

I’m not to sure how exciting a blog post this is to others. But for me it’s some of the final parts required to complete the mating of S85 V10 and E46 M3, and they are some REALLY special parts.
KMS Racing Engines in Holland are BMW racing specialists. Working with the geniuses at Cosworth in the UK, they have developed some of the most comprehensive plug and play packages for the S85 V10, S65 V8, S54 Straight 6 and probably a host of other engines.
Excitedly pulling open the package and popping it on the floor to look over and photograph really isn’t doing these components justice, but the sooner I get it all fitted, the sooner we can get the car running. Posted Image

Pectel SQ6M-12 Pre-loaded with an S85 V10 Configuration file, and map that we’re told should see us around 600bhp. Even the protective covers for the sockets are amazing.
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Even without plugging it in this Cosworth Pi Omega Dash looks awesome.

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The External Oil filter housing and block connector with new sensors.

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One of my favourite parts, the KMS Racing Engines designed and built mechanical throttle linkage. This replaces the fly by wire motors using all original mounts, and is machined with gearing inside to control both banks of the V accurately with one throttle cable.

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A big thank you to John and William from KMS Racing Engines, for creating this awesome package of parts, and to Cosworth for providing the Pectel ECU, and the Formula 1 quality motorsport loom.
Trackculture/KMS/Dynotorque/Cosworth/Pectel V10 E46 M3

#18 Blackadder

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Posted 01 October 2010 - 04:31 PM

I really don't want a cage, but I do intend on doing 200+mph in it, so I really should! If I do, I'll try and keep it 'covert'..
It's already got 6pot 360mm front brakes with Pagid blues, and 4pot 360mm rears. It's also got HSD coilovers, H&R anti roll bars, powerflex bushes CSL seats and steering wheel. I've got some new lips and polished centres for the wheels, that I'm about to build up that will give it a 11.5" wide rear for the 285/30/18 Federal RSR track tyres. It's basically ready to go once the engines done.


That's seriously fucking awesome and a real inspiration. Hope I have a hardcore daily like this one day :P
Dan

Traction control???? Wash your mouth out with soap!!!!


#19 SteveDunn

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Posted 04 October 2010 - 01:36 PM

Love it.

#20 Willis

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Posted 04 October 2010 - 01:46 PM

Such a great build. Love the way you have solved problems and just made them into ways to showcase how knowledge of ALL cars and not just one make can really help you out of situations that look either impossible or very very expensive and time consuming. Great work so far, will eagerly wait the finished result!!




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