M3 track day car conversion

All the info you need to race E30's

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UweM3
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Tue Oct 16, 2007 8:25 pm

Own this M3 for 8years now and the brown cancer was taking over.
There was only one option to keep the car in a reasonable condition without robbing a bank. Strip it and cage it! :D

What really kicked it off was all the water constantly soaking the carpet. Sometimes 2" high in the passenger footwell. Or the glove box FULL to the brim.
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So out came the carpet and after 3-4 weeks without the carpet (nice race sound inside :D ) the rear bench and after that.........

slow start, removing the tarmac inside
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I stripped out as much as possible before taking the car to ETA Motorsport (opposite Brands Hatch) to get a cage welded in.
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Matt at ETA didn't waste any time, I got round there the following week and the whole car was stripped down!! I was shocked when I saw the car, nothing was left, just the shell and the rear axle!! Wasn't prepared for that.
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I knew it wouldn't be pretty.....
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just a little bit of cutting rotten metal out here and there
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an replacing it. Nothing major..... :cry:
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out came the sunroof
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and some other bits.
--aux tank
--central locking
--complete ABS (didn't work anyway, but still wish I would have kept it)
--every wire which wasn't connected to anything
--all sound deadening
--parcel shelf
--stereo amp and speakers
--OBC

after the shell was welded/repaired Matt started with the cage. Main hoop first.
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to cut a long story short, approx 35m of CDS tube later we ended up with this.
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after painting (the colour looks much lighter in the pictures)
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added some grip tape to the floor and my new bucket seat
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I am really happy with the outcome of the whole project. In my wildest dreams I wouldn't have imagined how much work that really would be. Big thanks to Matt from ETA Motorsport who really worked his a*** off the get the car ready for my trip to the NÃarbring.

I have been to the Ring 3 times this year and done Brands Hatch twice. The car is a blast to drive and I can only recommend to anyone who is serious about trackdays and the Ring to weld a cage in. It has transformed the car. It handles so much better and taking all the weight out has really made a difference. It's a pain for daily driving (have got another car, but can't stay away) but as soon you are out on the track it's all smiles.

Well not always. on the way home from Brands Hatch (after 250 miles on track without a single scratch!) I had the urge to smash the M3 into the back of a new 320d going into Dartford tunnel. oops!
Car was looking rather sorry and had to stay with the bodyshop for a few weeks. While it was there, some more rust was sorted out and the whole car was sprayed glossy black. Haven't got proper pictures of that, but it is sooo shiny.....

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maxfield
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Tue Oct 16, 2007 8:27 pm

8) 8)
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Lloydie38
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Tue Oct 16, 2007 8:44 pm

Wow what a project, How long did it take from start to finish?
The Isle of Man: No National Speed Limit, No Gatso's, No Nanny State, a disused airfield track 1.5 miles long, the best mountain road to drive on...Come and Play!
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Tue Oct 16, 2007 8:45 pm

very very very nice!!! i like very much indeed.... :D
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northloop
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Tue Oct 16, 2007 9:07 pm

Looks very pretty, although it's missing a northloop sticker or two :wink:
UweM3
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Tue Oct 16, 2007 9:10 pm

northloop wrote:Looks very pretty, although it's missing a northloop sticker or two :wink:
ordered one today :P
UweM3
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Tue Oct 16, 2007 9:18 pm

Lloydie38 wrote:Wow what a project, How long did it take from start to finish?
about 3 month. Matt was really working overtime. Sometimes till 10 pm on Fridays!

Forgot to mention a few things. While the car was at ETA I had taken the the front suspension off

-- new lower wishbones
-- new tie rods
-- Steering rack rebuild
-- front subframe re-inforced (selfmade kit, got some left of that)
-- new wheel bearings (E28 --> much cheaper!)
-- replaced front ARB mounts with Delrin (selfmade)
-- adjustable top shock mounts (selfmade)
-- new brake disks (300mm conversion, selfmade)
-- new propshaft center bearing (was nothing wrong with the old one :cry: )
-- new propshaft coupling (again, nothing wrong with the old one :cry: )
-- rebuild gearbox

a bit later was a 3.64 diff fitted.
maxfield
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Tue Oct 16, 2007 9:19 pm

How much of a difference was the 3.64?
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UweM3
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Tue Oct 16, 2007 9:25 pm

maxfield wrote:How much of a difference was the 3.64?
quite noticable. "crusing" over to the Ring is abit of a pain. Doing around 4400 at 70mph. But that's on to small tyres (225/35).
I am going to fit 225/45/16 as road tyres (bought some nice BBS on Ebay) which will hopefully get a few hundred rpm off. 4000rpm is quite ok, but anything more requires earplugs on long journeys (--> Carbon airbox as well)

Acceleration is really good and top speed doesn't suffer too much (where can you go flat out anyway??)

On the Ring it's not that optimal (but was running 235/40/17 which makes it longer again). Was running out of revs at a few places. Just hope with the 225/45/16 it will be a bit better.
oldroydsr4
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Tue Oct 16, 2007 9:46 pm

Out of interest what was ETA like for cost.

I have a touring turbo that requires a cage/ sun roof cutting out and wiring loom cutting down etc.

However no rust tho (already been sprayed etc)

If you don't want to post on a the forum your welcome to Pm me.

by the way the project looks stunning.

cheers
UweM3
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Tue Oct 16, 2007 9:56 pm

oldroydsr4 wrote:Out of interest what was ETA like for cost.

I have a touring turbo that requires a cage/ sun roof cutting out and wiring loom cutting down etc.

However no rust tho (already been sprayed etc)

If you don't want to post on a the forum your welcome to Pm me.

by the way the project looks stunning.

cheers
It all depends on how many points you have. My cage (11 points) was 2500 ish. But that included the wiring and stripping out.
JimmyC
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Tue Oct 16, 2007 11:25 pm

Nice, very nice

Get some pics up of it in the new paint :cool:

3 months is impressive!! I'm just over the 2 year mark on mine :o

With all these zone track projects we'll all have to meet up for a trackday :D
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Wed Oct 17, 2007 12:31 am

out of interest.. how much extra does the 300mm brake conversion weigh? (yes being sad about unsprung mass..)
Got cable ties? Get diffin..

Arch roller for hire.

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northloop
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Wed Oct 17, 2007 7:40 am

UweM3 wrote:
northloop wrote:Looks very pretty, although it's missing a northloop sticker or two :wink:
ordered one today :P
I know you did because i'm the one who will be sending it to you 8)


What have you got going on with the side impact bars. Have you left part unpainted or is that a protective covering? If so what is it please?
UweM3
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Wed Oct 17, 2007 7:53 am

Jhonno wrote:out of interest.. how much extra does the 300mm brake conversion weigh? (yes being sad about unsprung mass..)
I haven't had the chance to weigh it, but it is quite a chunk.
The bigger caliper isn't too bad, but the disk is heavy. I have drawn a disk
on CAD and mailed to 3Gbrakes to obtain a quote for a 2 piece disk, but they are working very very slow and I have to ring them up to chase just for a quote! Doesn't encourage me to order a disk there....
(maybe try BG development next)

I don't mind the additional weight (yet) because the brakes work so much better than stock. I ruined a set of disks (was impatient and didn't bed pads in properly) but have done the Ring twice and Brands Hatch with one set of disks with no judder whatsover. I can use bog standard road pads for track, but you need to keep an eye on wear. But for £25 a set I don't care (yet)

don't know if there is difference in handling driving, hard to tell if you can't do a back to back comparision. All I know is that I am going to a track day and don't have to worry about brakes. I do have ducts going right to the centre of the disk.

I would like to find a slightly uprated pad (Pagid fast road would have been ideal, but NLA) with less wear but don't want much more friction.
They work fine with the roadpads for my taste. I had Pagid RS29 fitted and the bite was enormous! Far too much, I could look the front wheels at any given speed, not joking!

Friend of mine has done the same conversion and fitted Pagid blue. Did 50 laps on the Ring and they looked like new!

Have also driven a car with PFC pads and they worked very good. But again, very high friction pads. Disks looked very good with these pads, no discolouration, smooth friction ring

Another option would be to use a 315mm disk (to piece custom mande) with E36 M3 calipers, but to be honest the 300mm works fine and fit's under 16" rims with ease. I am sure with the right rim even a 15" would be possible. The E32 (which are the calipers from) was running 15" with 302mm disk

pic of the 300mm setup
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UweM3
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Wed Oct 17, 2007 8:11 am

Don't know if this is a M3 only problem, but my front subframe was cracked around the engine mounts.
I have a reinforcement kit available to stop this.
Please have a look in the for sale section

http://www.e30zone.net/modules.php?name ... 818#874818

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essfourteen
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Wed Oct 17, 2007 8:37 am

JimmyC wrote: With all these zone track projects we'll all have to meet up for a trackday :D
Keep watching the events forum then.. I have got three already planned for next year (March, July, October) and am trying to slip another one in before Christmas.. and there is the possibility of an all Zoners day if I can get around 40 of you lot interested.

Nick
essfourteen
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Wed Oct 17, 2007 9:01 am

UweM3 wrote: The E32 (which are the calipers from)
Do the E32 calipers bolt right up and work.. or do you need an E32 m/c as well?
UweM3
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Wed Oct 17, 2007 9:19 am

essfourteen wrote:
UweM3 wrote: The E32 (which are the calipers from)
Do the E32 calipers bolt right up and work.. or do you need an E32 m/c as well?
the calipers do need some machining. but nothing major. I have used them with the M3 MC for a while which works fine, but felt that the front rear balance wasn't right and have fitted a E32 MC now (from C3BMW)

there caliper bracket needs to be machined as shown in the picture.
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schuey
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Wed Oct 17, 2007 9:30 am

That car is great :cool:
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318 IS. Sold.
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buster
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Wed Oct 17, 2007 9:32 am

i thought you need to use e34 540 calipers for this brake conversion. ?
Im going to do this on mine as i felt the standard brakes were ok around croft,they could have been better.
playo
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Wed Oct 17, 2007 9:41 am

Great work Uwe!!

Always a pleasure reading your posts 8)
UweM3
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Wed Oct 17, 2007 10:51 am

buster wrote:i thought you need to use e34 540 calipers for this brake conversion. ?
Im going to do this on mine as i felt the standard brakes were ok around croft,they could have been better.
E32 735i, E32 750i, E34 540i all the same.
just watch out for the E32 730i which is 302 as well, but a thinner disk.

most of the BMW calipers seem to have equal bolt spacing. It's just a matter of finding one with not too much offset.

I am sure there are other suitable calipers, just don't have the opportunity to go to a proper breaker and try them all out.

4pot Brembo's from the E32 will bolt on with no problem. Just need to find a suitable disk. The E46 M3 disk will fit, but only with a 12.5mm thick spacer UNDER the disk mating face. Not an option for me, ET+12.5mm
Last edited by UweM3 on Wed Oct 17, 2007 11:08 am, edited 1 time in total.
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buster
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Wed Oct 17, 2007 10:59 am

UweM3 wrote:
buster wrote:i thought you need to use e34 540 calipers for this brake conversion. ?
Im going to do this on mine as i felt the standard brakes were ok around croft,they could have been better.
E32 735i, E32 750i, E34 540i all the same.
just watch out for the E32 730i which is 302 as well, but a thinner disk.

most of the BMW calipers seem to have equal bolt spacing. It's just a matter of finding one with not too much offset.

I am sure there are other suitable calipers, just don't have to opportunity to go to a proper breaker and try them all out.

4pot Brembo's from the E32 will bolt on with no problem. Just need to find a suitable disk. The E46 M3 disk will fit, but only with a 12.5mm thick spacer UNDER the disk mating face. Not an option for me, ET+12.5mm
Not an option for me either as im running standard e30 arches,its tight with the standard m3 brakes as it is.I've got a pair of 4 pot brembos also but just no room for them unless i change the wheels.It looks like this 300mm disk is the upgrade i am after,pitty i didnt realise earlier as the gen bmw m3 ones have only been on a few months :(
Are the Mercedes Benz W124 E500 or R129 the disks you used ?
UweM3
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Wed Oct 17, 2007 11:00 am

playo wrote:Great work Uwe!!

Always a pleasure reading your posts 8)
thanks for the comment. I am always a bit unsure about writing. english is not my first language and sometimes I do write a bit crytic winkeye
UweM3
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Wed Oct 17, 2007 11:07 am

buster wrote:
UweM3 wrote:
buster wrote:i thought you need to use e34 540 calipers for this brake conversion. ?
Im going to do this on mine as i felt the standard brakes were ok around croft,they could have been better.
E32 735i, E32 750i, E34 540i all the same.
just watch out for the E32 730i which is 302 as well, but a thinner disk.

most of the BMW calipers seem to have equal bolt spacing. It's just a matter of finding one with not too much offset.

I am sure there are other suitable calipers, just don't have to opportunity to go to a proper breaker and try them all out.

4pot Brembo's from the E32 will bolt on with no problem. Just need to find a suitable disk. The E46 M3 disk will fit, but only with a 12.5mm thick spacer UNDER the disk mating face. Not an option for me, ET+12.5mm
Not an option for me either as im running standard e30 arches,its tight with the standard m3 brakes as it is.I've got a pair of 4 pot brembos also but just no room for them unless i change the wheels.It looks like this 300mm disk is the upgrade i am after,pitty i didnt realise earlier as the gen bmw m3 ones have only been on a few months :(
Are the Mercedes Benz W124 E500 or R129 the disks you used ?
disks are W124 E500 but think R129 is the same (if that's the code for SL's)

Track changes only 1mm per side

GSF part code for Brembo disks is M60163

I have a drawing of the machinework required. Sorry it's in german. Can translate if it doesn't make sense. But basically you only need to enlarge the centre bore (use an old wheel bearing to try) and elongate the 5 holes of the Merc's PCD 112 to 120. I have used a mill and a divider head, but the last two sets I have just filed the holes till the fitted over the bolts.
Just a lather required for the centre bore.

I have used the Brembo disk from GSF and a OEM Merc disk (which I ruined....) and they perfom equally. So £65 GFS then :D

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buster
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Wed Oct 17, 2007 11:09 am

thanks Uwe :D
I work in a machine shop so this will be a doddle 8)
It would be possible just to drill another 5 holes the other way up on a 120 pcd.Might make it a bit lighter also
UweM3
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Wed Oct 17, 2007 11:19 am

buster wrote:thanks Uwe :D
I work in a machine shop so this will be a doddle 8)
It would be possible just to drill another 5 holes the other way up on a 120 pcd.Might make it a bit lighter also
why drill more holes? the thing will look like a swiss cheese :D

The brake disk doesn't rely on the bolts to transmitt the forces anyway, but on the clamping pressure. So every reduction in surface isn't a good thing IMHO. Why weaken it with more holes? the weight reduction will be next to nothing and is so close to the centre that it will not make any difference.

You will have to fabricate a little jig for milling the caliper bracket. I couldn't get the glide pins out, so my jigh looks a little bit wierd.
I turned the caliper mounting screws flat and used them to line the lug holes up. Not the best way of doing it, but it was all I had available that day.

Let me know how you get on.
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Weeman
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Wed Oct 17, 2007 11:26 am

Uwe, where did you put all the wires etc, that usually are fixed to the trans tunnel etc?? I need to de tar and cage mine soon, but was unsure what to do with the wiring issue.

Looking great btw
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buster
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Wed Oct 17, 2007 11:28 am

ok cheers,fair point on the holes.
I'll keep you posted.
UweM3
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Wed Oct 17, 2007 12:51 pm

Weeman wrote:Uwe, where did you put all the wires etc, that usually are fixed to the trans tunnel etc?? I need to de tar and cage mine soon, but was unsure what to do with the wiring issue.

Looking great btw
Matt from ETA has sorted all the wiring out. Was a bit frightening to watch him with the wire cutter. My loom was lying beside the car and he was chopping all sorts of wires off!

fitted the loom back in and EVERYTHING worked. Was well chuffed.

everything is running left and right hand sill, nothing in the middle.
From what I remember it's only the reverse light wire causing trouble. Everything else can be re-routed, my electric window switches are in the dash board above the (former) radio.

Other stuff is hidden behind the rear bulkhead. Very clean look.
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Weeman
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Wed Oct 17, 2007 2:11 pm

electric windows Ghey!!!! lol

Thanks dude, I might leave em where they are, I couldn't wire a plug most of the time let alone a car, I'd end up killing myself by a combination of 12v battery shock and subsequant hanging by said wire as i fall over :)
UweM3
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Wed Oct 17, 2007 3:30 pm

Weeman wrote:electric windows Ghey!!!! lol
just imagine. driving to Brands Hatch. Sitting strapped in a bucket seat with six point harness. Going over QE2 bridge with a left hand drive car.
How are you going to open the right hand window to toss the coin into the basket????? winkeye
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Wed Oct 17, 2007 4:32 pm

I love this car! having been out in it.. Many thanks Uwe for that ride, i haven't stopped grinning yet! :D :D :D

Got my diff now so should be back home in MK this coming weekend to install it. That seat is a dream! Drove to Bristol and back to tomson's place to get the diff and not once did i feel uncomfy!

Well worth the money! winkeye
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Wed Oct 17, 2007 5:27 pm

i take it the inside has been painted in the above pics the floor loks so shinny am i right matey is this comon practace as i am stripping mine at present and the floor looks grubby and dull not like yours

great car :cool:
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