Starkfu's E9XTC build thread - JB E90 M3

[starkfu]

Looks like HFC's aren't an option due to clearance, they would fit, but stick out 2 inches below the lowest point on the underbody.

so I am having the factory cats welded back on to the Borla X-pipe for now and considering moving to a ARH header option when I get the S/C.

Should have the car back this week and then off to get tuned at TTFS.

I will take some pics when I get it back and update.

[starkfu]

update - car is home, had an issue with the right front caliper locking up - pulling it apart to investigate now..... everything else is beautiful...

Pics soon!

[starkfu]

So apparently the front right caliper carrier lower bolt backed itself out.... I triple checked ALL torque values and it fell out while I was driving resulting in the caliper pivoting upon braking.

I ordered 4 new carrier bolts and replaced all 4 just in case.... then I noticed during the shakedown that my blower fan wasn't working..... found the infamous fried blower motor wiring... thankfully I had a spare resistor on hand already, just ordered new plug and pins to fix this....

THAT BEING SAID....

I'm going to wash it tonight and go to C&C in the morning and take some pics - then maybe stop at the train depot and take some shots!

PICS COMING I PROMISE!!

[starkfu]

Sorry for the delay - my car is 100% done for this phase of the build. Next phase will start at the end of my driving season here in VA which should be around Thanksgiving.

Final Details: Tune was completed at TTFS and the first dyno run I saw was at 318 HP (post mods - I did not get a pre-mods Dyno run). I was told by some acquaintances that TTFS dyno is traditionally low, curious to see what numbers it would put down on others. GTS software made a noticeable difference and the car feels like a whole new beast post tune!

Final dyno run: 364.6 HP / 290.3 ft/lbs



Also my final alignment specs after RRT did the alignment and camber plate adjustment - again, super happy with the ride quality - firm, but not too bouncy.



Here she is right after getting it detailed



HVAC fan was not running - did some research and discovered this common issue was present in my car - thanks to a thread on this forum, I was able to find the pins and connector blank in order to cut this one out and extend my wiring to a new connector and provide a drip loop in the wiring - all wiring soldered and shrink wrapped.



Then, because I don't like random unfinished holes in my interior - I bought some 1 1/2" desk grommets and drilled out the area just above the rear adjustment knob for the bilsteins and put the grommet in the hole.




A few other random shots of the exterior.







Phase I built - high level mods list:

Bilstein PSS 10 suspension
Vorshlag camber plates
Turner Aluminum / Derlin subframe and diff mounts
Powerflex rear inner bushings (both sets)
Powerflex rear sway bar bushings
Borla X pipe (with factory primary cats welded back in)
Borla ATAK
Macht Schnell Stage II intake
Macht Schnell Pulleys
Bimmerworld baffled PS resevoir
TTFS tune with GTS DCT software
Hawk street / track pads (noisy and dirty - but stops her on a dime)
Bridgestone Potenza RE11's
ALL fluids baselined @ 95K miles
All 6 rear upper control arms replaced with stock
Flex disc and center bearing replaced with stock
Transmission mounts replaced with stock
Motor Mounts replaced - Group N solid
EDC emulated out



Plans for Phase II over the next winter period:

Front suspension refresh & aftermarket bushings
Rod bearings and relevant gaskets replacements
Plugs
BBK front and rear (researching now)
ARH headers with cats
New tune
Speaker replacements & Nav map upgrade
Rims - BBS FI or equivelant


Phase III - two years out

Final prep for supercharger
Cams? (researching now)
Harrop Supercharger (hoping stage II will be available by then)
Any paint work necessary


Phase IV - if needed

Forged internals

[starkfu]

I did forget to mention one thing - I am looking at some exterior mods too....

I am not 100% sold on the TEE carbon canard look - I have a single issue with it - the rear of the canard doesn't match the e90 bumper very well - I have a few ideas to help it mesh a little better, but I'm just not sure yet.

So I am looking at rear diffuser, I am liking the type II style (simple small and a clean look) couple with the carbon canards if I can get them to look right.

Carbon side skirt extensions - I really like the look of these:

https://www.dinmann.com/collections/...rts-bmw-e90-m3

And for the front lip I like the Vorsteiner GTS-V style

Still looking at trunk lids as I'd like to ditch factory spoiler and have some sort of built in dove tail - might get the lips first and then Photoshop to see what looks best.

Hood I will stay stock or carbon equivalent, no new vents or anything though.

Carbon side market bezels need to go on too.



This may happen this summer yet or over winter - depends on how my contract negotiations go!

[starkfu]

The carbon canard gap can been seen pretty well in this picture towards the right of the canard....



This grates at me so much!! the quality of the product is good - I don't blame TEE at all - but these were made for e92 and not e90.... I am thinking about making new holes to recess them a little further into the middle of the car to hide the gap some, but don't want to go making new holes without mocking it up first.....

also thought about making a mold to make my own...

Meh - we will see.

[starkfu]

So..... I've been out of pocket for some time.

Long version - not worth my effort to type....

Short version - don't fuck with the IRS...... EVER!!!!!!

Good news is that I walked out of it with a voluntary profitable sale of my 2nd home and all of my assets in tact.

E90 left off with phase 1 of my build being completed. I'm happy with the car, few quick notes:

RE11's lasted a usable 18K miles, I ran them for another 7K until I had a blow out on the freeway. Car came out of it unscathed and is currently sitting on my 19" e46 wheels with Federal tires.

Since RE11's aren't readily available anymore - I went with Michelin PS2's, they are getting mounted this week.

Hawk High performance street/track pads deteriorated really really quick - I mean like 20k miles quick - I'm out of brake material in front and the rotors are scored.

Rear of the car is a bit too low - I don't like the loading through corners when I accelerate, the car doesn't like it either. Feels like an FC3 RX7 launching rough.

So - I have an order in for the following:

Turner front arm monoball conversion

sway bar bushings for front

New front lower control arms

rear outer carrier bushings that I didn't do during the rear refresh

Front rotors and pads (rear brakes were fine)

I also ordered a quickjack as I used one at a friends house and fell in love with it - no more 2x10's to get my car off the ground!!

Fluid swap will happen at the same time.

After the car is re-baselined - fluids swapped - tires on and aligned, then we can get back to the fun.



Oh - I also picked up an E39 540i. $1,700, needed a hood, passenger fender, passenger headlight, and front bumper. The chain had also hopped a tooth on Bank 2 intake sprocket. So I have it apart and am almost ready to reassemble. Originally bought it as I was afraid all my assets were going to be seized, but thankfully they were not.

*Future plans -

I'm revamping some of my future plans - next phase of work will include heavy DCT mods from SSP, entire cooling system revamp, BE bearings and ARP bolts, and then rims and exterior mods.

Will do my best to keep this up to date as I go!

[Drifter2090]

Great read! Can't wait to see whats next, give us more pics!