Craig's 328i Sport - e36 Track Car Build Thread

Craig's 328i Sport - e36 Track Car Build Thread

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Craig!

Original Poster:

349 posts

197 months

Friday 28th May 2010
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Here's a little update which also reflects on the stories above; Well the tar removal carried on and the following pieces were removed; Spare Wheel Well, Rear Quarters, Rear Bench, Rear Boot Panel and Inner Arches. I also re-fitted the grey rear boot carpeting and my cargo net which secures down anything in the boot as with the seats removed there is no form of rear bulkhead.













I then decided to treat the car to a nice holiday in Germany, here’s some pictures from a few of the small towns around Nurburg where we stopped for lunch. The first two pictures are of the car in Cochem the next two were taken in Altenahr, both places are worth visiting if you are in the area!!









The car was performing near faultlessly all weekend, and it really is punching above its own weight considering it’s meant to be the underdog compared to the M3. The turn in is very sharp, very little feel of under steer and phenomenal levels of mechanical grip. Of course the extra 100bhp would be nice when it comes to the fast uphill sections, but apart from that I am taken back by the capability of this car.

I’m not into timing, however one passenger I took out timed me doing an 8:59 in traffic, the same person also followed the 328i out for a lap in manic Sunday traffic and got a 9:11 with plenty of hold ups. The big surprise came when it turned out a Subaru behind me on a quiet lap had a camera sneakily mounted to a motor, he was behind me the whole lap and his video shows him completing an 8:38 with me crossing the gantry a few seconds before him.

The one small niggle I did have was a minor one, but it could have lead to a major problem if it wasn’t spotted in its early stages. On one outing, after coming out of Schwalbenschwanz it sounded like a rear bearing had collapsed, coasted off and noticed that below 60mph the noise wasn’t there. Upon further inspection you could see that when the wheels had been refurbished the backs of the wheels which touch the hub had also been painted. Now in April this did not prove to be a problem, however in May with the temperatures a little higher you could see where the paint had gone soft and ‘squeezed’ itself from the back of the bur causing in effect the wheel to come loose. A quick tighten and all was fine, this is one to keep on top of and if need be the paint will be removed. The picture below shows the little strands of paint that have been forced out between the gap.



Below, some all important action shots.





The car has since made it home and been given the once over, all bushes and bearings have been checked plus the brakes have been stripped down and inspected; the front pads have around 25% wear and the rears around 50%. The BMW seems to wear pads at the rate of roughly two rears to every one set of fronts, the pads are wearing well given they have completed over 600 track miles.

The only problem of concern which came to light during the trip home is the from passengers side wheel bearing rumbles a little, upon further inspection it sounds dry however there is no play... this will be replaced within the next few weeks as a matter of course.


Edited by Craig! on Friday 28th May 19:30

S3_Graham

12,830 posts

199 months

Saturday 29th May 2010
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craig do you have new bolts for your split rims yet?

Craig!

Original Poster:

349 posts

197 months

Saturday 29th May 2010
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Not yet no, there still just sat gathering dust at the moment.

sniff diesel

13,107 posts

212 months

Sunday 30th May 2010
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Craig! said:
Not yet no, there still just sat gathering dust at the moment.
Are you planning on restoring them to original polished condition Craig? I've just aquired another 328i as a spares car with a set of staggered BBS rims, the fronts are absolutely mint and the rears still good if not as mint as the fronts. Was going to get an advert up but you can have first dibs if you wanted.

joe_90

4,206 posts

231 months

Sunday 30th May 2010
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Hey Sniff, what size are the backs? I have 4 recon'd BBS splitrims, but they are all the same size. I really wanted a staggered set.. (maybe a swap, they have tyres on too)

Going to get another thread up soon of the e36, Just spent over 1K at Redish motorsports.. Just waiting to go and get the bits now.. (when I have 5 mins)

Most odd, I was ripping out the inside, and under the back seat the whole thing was soaked in oil!!.. Most odd, however it ment that the sound deading just peeled off.

Also, im in two mins to remove the heater box, as i know it weighs a bit, but, the front demister could be useful on track days.. Also I guess the dash needs to come competly out to remove it?


Edited by joe_90 on Sunday 30th May 21:20

sniff diesel

13,107 posts

212 months

Sunday 30th May 2010
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joe_90 said:
Hey Sniff, what size are the backs? I have 4 recon'd BBS splitrims, but they are all the same size. I really wanted a staggered set.. (maybe a swap, they have tyres on too)

Also, im in two mins to remove the heater box, as i know it weighs a bit, but, the front demister could be useful on track days.. Also I guess the dash needs to come competly out to remove it?
Rears are 8.5" RC042's fronts are 7.5" RC041's, I've got 5 sets of these BBS rims so could really do with selling a couple rather than swapping sorry. I'll get some proper adverts up in the classifieds.

I'd leave the heater box and demister in TBH, I doubt it weighs 10kgs combined, and would certainly gain a lot of time compared to a misted up screen on track. A useful bonus is it'll give the cooling system another couple of litres to play with which can make all the difference if cooling performance is marginal.

joe_90

4,206 posts

231 months

Sunday 30th May 2010
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sniff diesel said:
joe_90 said:
Hey Sniff, what size are the backs? I have 4 recon'd BBS splitrims, but they are all the same size. I really wanted a staggered set.. (maybe a swap, they have tyres on too)

Also, im in two mins to remove the heater box, as i know it weighs a bit, but, the front demister could be useful on track days.. Also I guess the dash needs to come competly out to remove it?
Rears are 8.5" RC042's fronts are 7.5" RC041's, I've got 5 sets of these BBS rims so could really do with selling a couple rather than swapping sorry. I'll get some proper adverts up in the classifieds.

I'd leave the heater box and demister in TBH, I doubt it weighs 10kgs combined, and would certainly gain a lot of time compared to a misted up screen on track. A useful bonus is it'll give the cooling system another couple of litres to play with which can make all the difference if cooling performance is marginal.
Ahh ok.. how mnay rc042's do you currently have? And what roughy would you want for a pair.

Also you change the exhaust? As im worried that it will push it over any sensible noise limit.

Edited by joe_90 on Sunday 30th May 21:32

fabienne

64 posts

267 months

Sunday 30th May 2010
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Excellent posts and great project keep up the good work.

sniff diesel

13,107 posts

212 months

Sunday 30th May 2010
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joe_90 said:
[Ahh ok.. how mnay rc042's do you currently have? And what roughy would you want for a pair.

Also you change the exhaust? As im worried that it will push it over any sensible noise limit.
PM'd about the wheels.

I've still got the standard exhaust for now, with the valve in the second tail pipe left permanently open. It would take a decat and a noisey stainless back box to push it over 95Db.

Craig!

Original Poster:

349 posts

197 months

Tuesday 15th June 2010
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Hi Rich, thanks for the offer but I'm just going to refurb my all if I'm going for BBS's. By the way sent you an e-mail several weeks ago through PH did you ever get it?

Craig!

Original Poster:

349 posts

197 months

Wednesday 16th June 2010
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Well I finally got round to replacing the passengers’ side wheel bearing, first things first though before any work could commence I needed a wheel bearing. Phone the dealers and got a few quotes, now the bearing comes as a complete unit; hub with the bearing pressed into it. This certainly would make the job faster, but at the same time five times more expensive.

I decided to look into other alternatives, one been pressing a new bearing into my current hub. Now fortunately for me, I remembered I still had the 328i Sport hubs sat in the garage and began cross referencing parts on the off chance they are the same... and they are, bonus!!

So before I even decided to get the car up in the air, I thought it would be best if I split down the 328i hub ready for fitting. The job in itself was simple enough if you have the right tools the main one been a 46mm socket to loosen off the centre hub.

Start with removing the brake callipers then the brake disc, next use a screw driver to prise round the outside edge of the centre hub cap. I resorted to tapping all the way round it with a hammer and screw driver to break the seal, and then with a simple twist of a large flat bladed screw driver it simply popped out. With the cap removed the next step is to loosen the hub nut which will require a breaker bar at the very least, you may even have to resort to Mr Scaffolding Pipe too if it’s not budging, don’t forget to also bend the metal locking tab back before loosening or you’ll be there all night.

With the centre hub loose the next step should be simple, slide the hub off the front upright. If it fails to move with ease you may need a slide hammer, the most effecting slide hammer for this job is fit your brake disc onto the hub backwards with the wheel bolts in by a few threads and simply ‘bang’ the disc back and forth between the hub and the wheel bolts.

You should now have the hub off, and all the following parts;



My 328i hub came off intact without any problems, so next step was to get the car up in the air and remove the same parts and slide on the new hub unit, simple, right!? No, when I attempted the task on the car which has the M3 Evo hubs I was left with the inner race off the wheel bearing firmly attached to the hub.



There is two ways in which this inner race could be removed, one was to cut a fine slot into the race with a dremel then simply split it with a chisel and a swift hammer blow the other method is to use a set of pullers with fine enough jaws to grab the machined lip on the inner race, you cannot get behind the race due to the brake dust shield been in the way. Believe it or not all my small pullers did not have fine enough jaws so I ended up resorting to this beastie which required two people (Thanks Dad!!);



I was now left with the old hub, inner race and seal off the car.



Now with the inner race off the car was ready for its new hub, I simply side the hub onto the upright, it required a few light hammer taps to get it sitting all the way on the shaft but jobs a good ‘un. Next was to fit the hub nut and torque it up to 300nM, refit the dust cap as well as the brake discs and callipers, fit the wheel and lower the car onto the ground and you’re done!

Here is my old bearing, you can see its shot inside just look at the ball bearing on the bottom of the picture. First sign of the problem came with a weird vibration which went away, jacked the car up and the bearing felt fine then it came back and got progressively worse. Upon the next check you could hear the difference between the sides, one bearing ran smooth, the other smooth but it had a grumble to it.

I also got round to one other minor task, on the way up the A19 after dropping off an e46 M3 CSL DSC unit to a guy who was in desperate need of one I lost a front kidney and the grill behind it, no idea how but fortunately I also had the old standard chrome ones which I took off.

First step was to wash it off the fairy liquid to remove all greases and grimes, next it was wet and dried down to give the surface a key and then I applied 3 coats of grey primer and 3 coats of gloss black paint. Unfortunately my camera died during this process so I only have the one picture.



Once again the car is back to 100%, apart from been used daily its next major outing is at RAF Barkston Heath for a sprint event, more on that later.

Craig!

Original Poster:

349 posts

197 months

Sunday 11th July 2010
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I mentioned last update that the cars next major outing was going to be at RAF Barkston Heath, well that’s been and gone which means an update is due. But where to start!?!

I’m rather new to sprint events, I really didn’t think it would take my fancy however a friend of mine put my name down for this event as one; it’d be a good weekend away with the lads and two; it was cheap, around £100.00 for two days on track and three; I think he wanted to see how I’d react in a competitive environment.

Fast forward onto Saturday, nice and early start set off at around 5:30am and arrived at Barkston Heath for around 8:00am. Pulled up at the gates and we were all escorted onto base, there was very few road car’s at this point everyone was towing a trailer with their pride and joy hidden undercover so I had no idea what the competition would be. Turned out that Saturday was a 16v Mini Owners Club track day followed by timed runs in the afternoon and Sunday was an RAF MSA event.

As everyone was unloading their Caterhams, Westfields and Mini’s with an array of engine conversions; Honda VTECs, Suzuki Hyabusas and Vauxhall Valvers I sat about wondering what the hell I had signed myself up for, and that feeling was even more pronounced when I saw the circuit... TIGHT is one of many words to describe it along with tactical, testing and challenging especially in a lardy road going BMW.

But this didn’t phase me, so I signed on and proceeded to number up the car;





First run out really did illustrate just how tight the circuit was, and the chicanes were so tight I had visions or me re-modelling them during the course of the day, in fact my first question to the clerk of the course was ‘are those white marker poles plastic or metal!?’ after all I didn’t want to risk serious body damage.

Fortunately for me they were plastic, as I proceeded to hit my first one. However the one I hit was on a small square base that wasn’t set level, so it ‘twanged’ up against the car making a neat white mark (which would later polish out) one thing it showed I was using as much as the track as physically possible, and I was consistent too as I hit it a second time *doh*.



I was obviously getting faster as the day progressed as the white lines got further and further down the wing!!

Afternoon came about and it was first of the timed runs, at first I didn’t pay much attention to the times and just used the runs as more track time and to play about with car control. However after I was informed the BMW wasn’t dead last, and in fact it was actually quiet far up front I started to take an interested and was hooked checking my times after each run, I had officially been bitted by the sprint bug.

Highlight of the day for me was also taking my friends purpose built V8 Westfield for a run, my god what a car!!

Sunday morning came thick and fast, and after a fantastic BBQ and evening with the 16v Mini Owners Club I was ready for the RAF MSA sprint. This was a whole different kettle of fish, most the cars from Saturday were competing but there was a lot more saloons and hatchbacks which made the competition a bit fairer but at the same time inside I didn’t want to be beaten. With the sign on and drivers briefing out of the way it was time to get down to business.



The course was slightly different for Sunday the last corner was a lot faster and this proved to be advantageous to me in the BMW as I could lay down some of its power. First few runs and it looked as if I had some stiff competition, I needed to switch my brain from track day mode into race day and stop worrying about getting the car home and just drive it properly. After a quick mental pep talk with myself I started to brake later and hold the power for longer and as the times showed this was paying off.

As the day came to rest and the final times were up and overall the BMW had come 10th out of 39 and in its class it was second only beaten by a really nicely prepared Subaru which looked far from standard, was I happy? You bet I was.



I also couldn’t resist getting this picture to, as it’s not often you get this kind of opportunity.



Sorry for the long post that really doesn’t have much about the build of the car, but after all its summer and this is the time where the car should be used. Next weekend it’s back out in Germany and then maybe after its return I’ll look at finishing off the interior and then planning the next moves.

S3_Graham

12,830 posts

199 months

Monday 12th July 2010
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Still looks lovely! do you think you will do any more events? Never competed in a sprint but went with a mate for moral support a few years back and it looked great fun.

andye30m3

3,453 posts

254 months

Monday 12th July 2010
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Cars looking great,

Very tempted to buy another M3 Evo and build a track day car myself.

Craig!

Original Poster:

349 posts

197 months

Thursday 15th July 2010
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I'll hopefully be doing a few more events over the course of the year!

Here's a video from the sprint weekend; http://www.youtube.com/watch?v=sTuiVAy8Wu8

Also worth looking at the V8 Westfield video as that car is an animal!


Edited by Craig! on Thursday 15th July 21:49

Craig!

Original Poster:

349 posts

197 months

Tuesday 9th November 2010
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This thread is long overdue an update, although not too much has changed I’ve just spent the last few months enjoying the car and making the most of the Summer / Autumn months.

First up, the Kumho V70a’s... I managed to get 8,000 miles out of the front tyres, and 11,000 miles out of the rears which to me is pretty impressive given that their track day tyres. Not to mention the fact that the car is used on track on regularly and driven spiritedly on most outings. As you can see from the pictures below they wore pretty evenly too, a sign that the geometry is correct.

Would I use these tyres again, yes without a doubt!!

At this very moment in time though, now the bad weather is here, I have a full set of Falken 452’s fitted and I also rate these, exceptional wet grip and feedback and pretty good in the dry too. A great ‘all year’ tyre which again I’d recommend.





The rear brake pads were finally up for renewal, upon changing them I noticed some cracks in the rear discs however the camera hasn’t really captured them.



I managed to get outstanding mileage with the Mintex 1155 front and 1144 rear set up, the fronts far out lasted the rears and still had 50% life left, but I changed them anyway due to the fact the front discs needed replacing.

Other than that, the only other work the car has had is another oil and filter change its still going strong at 177,000 miles.

Craig!

Original Poster:

349 posts

197 months

Tuesday 9th November 2010
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This next update is one not normally associated with a track car; paintwork restoration. I decided in August that the BMW was starting to look a little ropey for my liking due to all the tar, rubber and road grime so one weekend I set about cleaning it.

Now this won’t interest most but I started with washing the car, moved onto tar removing then the clay bar. Once these steps were done the paintwork was corrected with Meguires Polish #83 and Speedglaze #80 using a Kestrel DAS6 random orbital polisher with a mixture of Meguires, 3M and Lake County pads. The final steps were to treat all the black trims and give the car two coats of Dodo Juice – Purple Haze wax.

Below are the final results.









Couldn’t resist these two shots!!





lordlee

3,137 posts

245 months

Wednesday 10th November 2010
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Nice work and a labour of love that has turned out fantastically well IMO! Funny you have been on the detailing tip and playing with water beading. I just put the second layer of collinite 476s on the pork before she is belatedly tucked away for the winter. I spent a good 10mins admiring the tight beading and water run off! Perhaps we need to get out more! Anyway excellent work as she looks lovely!

Craig!

Original Poster:

349 posts

197 months

Friday 24th December 2010
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For awhile now I had planned to do track days at both the Nurburgring and Spa-Francorchamps, in April I was lucky enough to do the first Destination Nurburgring and now, after many visits to Spa as a passenger or additional driver I finally bit the bullet and booked for Monday 4th October through Circuit-Days.

The trip first involved a few days socialising at Nurburg, from the moment I left the house till the point we arrived in Germany it like been stuck in India during monsoon season! I feared that it was going to be a wet weekend, but the weather gods were on our side and as we rolled up at Adenau the weather was damp and foggy but the rain had eased up. The weekend just got better from there, on Saturday I was sat in a queue for fuel and the temperature gauge read 26.5 degrees in the baking sunshine!!!

Monday came, and we made it to Spa just in time after a few minor detours. Signed on, completed the drivers briefing and then after a few sighting laps we were good to go... they say pictures speak a thousand words;























The day was not without drama, we decided that the latest we could leave for the ferry port was 15:30 in order to make it in good time. I decided at 15:10 to do one last session, famous last words I guess but at 15:24 I saw the coolant light creep and amongst a lot of swearing I pulled over to find that the car had burst a coolant hose!!!



Panic set in, but fortunately the whole group chipped in and we managed to by-pass the hose that went from the block into the heater matrix valve using one of the existing pipes, this would leave the car without a heater but still least it would get us home. We had to make another sacrifice, the scuttle panel cover had to be cut off as we could not get the wipers to release, but this is easily replaced. Work complete the car was filled with coolant (read: tap water) and it was time to go, we left Spa at 15:57 and had some time to make up, but fortunately made the ferry with 6 minutes to spare!

All in all had a fantastic weekend, already planning to do some more days at Spa it’s a great circuit and gives a different ‘buzz’ to the ‘Ring, I’d happily drive both most weekend and not get bored!

Craig!

Original Poster:

349 posts

197 months

Friday 24th December 2010
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Well winters well and truly arrived, had a planned outing at Mallory Park booked for the 28th of November but that got cancelled due to the snow and the cars barely moved a wheel since then!

I managed to pick up a Rover 400 cheap, which very quickly got nicknamed Snover R400, to use through the snowy months... that is if it lasts that long, its verging on the edge of the dreaded head gasket failure and the massive mounds of snow I’ve rammed it through have started to pull its exhaust off at the flexi-pipe!

Anyway, less Rover talk; I now need to decide what to do with the BMW whilst it’s off the road. Do I leave it as it is, keep using it till it dies then let its soul rest in scrap heaven or do I spend some money on the old girl? To get the car exactly to how I want it to be, at the bare minimum would involve replacing the suspension (again!), fitting a roll-cage, fitting a different steering wheel, fitting a GT splitter and spoiler, replacing a rusty wing and maybe sort a few bodywork niggles out before the tin worm starts to spreads. This all costs money and that doesn’t take into account the worry that the car is now on 182,000 miles and could be due a clutch / gearbox / engine at any moment.

Decisions, decisions... What I do, like, no LOVE about this car is the fact that its stood for 4 weeks under a huge mound of snow and all I did was clear the snow, turn the key in the ignition and it fired straight into life as if it has only been run the day before!

Its moments like these that make me want to stick it out, keep the car and turn it into my vision of a perfect e36.