BMW M3 Forum (E90 E92)

BMW Garage BMW Meets Register Search Today's Posts Mark Forums Read


Go Back   M3Post - BMW M3 Forum > M3 (E90 / E92 / E93) > Regional Forums > Australia
 
BPM
Post Reply
 
Thread Tools Search this Thread
      08-20-2016, 08:55 AM   #1
perth1
Private
31
Rep
79
Posts

Drives: E90
Join Date: Aug 2016
Location: Perth, Western Australia

iTrader: (0)

Intro & My E90 M3 full replica build

Hi,
My first post on here. Prior to this I've been mostly on Fordforums,
but for over a year now I have had a damaged 2012 M3-wreck in my shed, and I have been collecting parts for building something out of it.

I'm an Engineer with an office job, but on my spare time for the last 25 years I have been panel beating, repairing and modifying cars, and also other things with 2 wheels, or some times repairing / restoring plant machinery with hydraulics.

Someone will for sure say 'Just buy an M3', but I think it's more fun to have built my own. My E92 M3-wreck is Stat. Writeoff, with ripped off front wheel, and my first idea was to build an E91 wagon with the M3 parts.
I have been looking for a cheap E91 for over a year now, but couldn't find a really cheap one, so now I have ended up with an E90 320 that I found on Gumtree with dead engine and parking-garage damage on both rear quarters, for almost free. It's dark blue, with cream interior, don't like the color of it, but doesn't matter as I will replace all panels on it except the doors and the roof. It may end up with a full re-spray to a different color by the time I'm done with it.

A month ago I have taken out the S65 engine & DCT trans of the wreck. The sump has a crack in it, and I have got hold of second hand sump and Right exhaust header for it.

I've just started stripping out the dead 320 engine of my E90, disconnecting hoses and removed the front bumper this weekend. Things will not happen quickly, depends how much is happening in the office, and if I get some days away from my office desk. I've noticed all fuel lines, brake lines etc. are different, so after both drivetrains are out I will be transferring the various tubes and sound insulation mats from the M3 wreck to the E90.

For the wiring harness, I was thinking splicing in the rear door plugs from the E90 harness into the M3 E92 harness. It should be possible to do that by studying the wiring diagrams carefully and patch this together over a few nights, but if this turns out to be too much of a nightmare, then I may try to buy a s/hand harness from an E90 M3 instead.

I'm just about to purchase an D-CAN to USB adapter, and see if I can figure out coding myself. May need some help from someone with more experience in this..

Anyway, this was just a quick first post.
Cheers,
Appreciate 1
IanMan382.50
      08-20-2016, 04:45 PM   #2
m3toboot
Private First Class
Australia
24
Rep
159
Posts

Drives: ///3
Join Date: Jul 2015
Location: Sydineeeeeeee

iTrader: (0)

GOOD LUCK with the project. Measure, test fit to ensure you can get engine/trans other major components in, then get bodywork sorted before fitting if you are changing colours etc.
Also check if this can be registered in your neck of the woods based on what you are planning. Would be a shame to go to all the work and find some silly paperwork gets in the way.
Might be 'easier' to transfer entire harness and then add e90 bits as needed...depending on what you are trying to achieve of course.

Again, Good LUCK!!!
Appreciate 0
      08-20-2016, 07:15 PM   #3
JJH
Major
JJH's Avatar
Australia
535
Rep
1,105
Posts

Drives: IB E92 M3 DCT; SG E90 325i
Join Date: Nov 2012
Location: Canberra, Australia

iTrader: (1)

Massive respect to you for even contemplating a project like this. I've seen/read of similar successful transplants like this, including an E91 in the UK on this forum. Good luck with it and keep this thread updated with your progress!!
Appreciate 0
      08-21-2016, 12:53 PM   #4
perth1
Private
31
Rep
79
Posts

Drives: E90
Join Date: Aug 2016
Location: Perth, Western Australia

iTrader: (0)

Thanks Guys,
In Western Australia there is an approval process for vehicle modifications that starts with submitting an application for approval in principle of the planned work.
I will do that soon before driving it on the road. (My E90 still licensed).
I don't expect much trouble with that part, as the body shell will not be modified other than the wider rear quarters.
For the drivetrain I will be exactly copying a model that already exists by the factory, so it should be easier to get it approved by WA DOT. I may need to find an automotive engineer to inspect and write a statement to go with my application.
The front sub-frame and rear suspension are both bolt straight in, with the same fixing points. The only difference I am aware of on M3 body shells are the small brackets for the front guards, and the plastic lid in the trunk above the muffler.
Before I had the E90 320 to put it into, I bought parts like s/hand E92 M3 front guard to complete the wreck. Then I discovered E92 guards doesn't fit against the E90 doors, so now I need to go to the local dealer and get two new E90 M3 front guards.
I also will need two new rear quarters for E90, and a new M3 bonnet. That lot will be quite an investment. I also need one new front brake disc, but other than that I should be complete with the parts I already have bought. I just got a new M3 transmission mount alloy bracket from the local dealer. It wasn't expensive. My Aircon compressor had a crack in it, but I took it to a aircon specialist in East Perth that had a spare back lid for that type of compressor, and it's now like new again. The oil lines for the DCT trans were damaged on my M3 wreck, and I just got a pair of 'new' ones from a wrecker in US.
As you suggested I will swap over the full E92 M3 harness, and all the modules. There will be some extra wires to add or transfer across for the rear doors, going towards the footwell module, and possibly towards the fuse box. I'm quite professional in doing wiring harness work, so it should be 'doable'. I haven't studied the details of it yet.
Cheers,
Appreciate 0
      08-21-2016, 11:57 PM   #5
CooLeh7
Private First Class
36
Rep
129
Posts

Drives: E92 M3 6MT
Join Date: Dec 2015
Location: Perth Australia

iTrader: (0)

Respect the challenge you gave yourself. Guess you will end up knowing your car inside out!
Probably know this but there are a ton of equipment that needs coding to the original VIN if changed or replaced......
Appreciate 1
      08-22-2016, 11:50 AM   #6
perth1
Private
31
Rep
79
Posts

Drives: E90
Join Date: Aug 2016
Location: Perth, Western Australia

iTrader: (0)

Hi CooLeh7,
Yes the programming will be the most tricky part.
In the first round I will move over all modules from the wreck into the E90 shell.
The ABS unit is crushed, and the footwell module is crushed. I have got S/hand ABS and footwell module from a same year M3, but getting them to work will require VIN change and other programming. The wreck didn't come from the auction with any keys either, but I have purchased a new specific Key fob for my M3 wreck over the BMW parts counter so that I can start it when it's ready for it.
My car will be for personal use for the next 5 - 10 years anyway, (not for sale any time soon), so if I get through the licensing modification inspection with the 'donor' VIN in the modules, then I may keep it that way for a while and deal with changing all modules to my body shell VIN at a later time.
Cheers,
Appreciate 0
      09-12-2016, 11:46 AM   #7
perth1
Private
31
Rep
79
Posts

Drives: E90
Join Date: Aug 2016
Location: Perth, Western Australia

iTrader: (0)

Hi again,
some photos of my DIY project;
The body shell, a cheap E90 with dead engine:


The dead base engine on its way out;


The engine bay of the E90 empty: Freddy Flintstone edition...


My parts donor, the 2012 M3, stat writeoff;


The S65 now out, and looking at the M3 specific tubes on left side of the bay, before starting to transfer them to the E90 shell:


That's all the photos for now. I have also trial fitted the M3 subframe into the E90 shell, it fits, but I need to install the fuel and brake lines before the subframe and engine can bolt in to its new home.

Today I took out the old fuel tank of the E90. I found several Redback spiders under there. Can't say I like working next to them, but I sprayed or squashed all I could see, so hopefully fewer of them next time I go under there.

Cheers,
Appreciate 0
      10-16-2018, 08:47 AM   #8
Rajvosa
Major
247
Rep
1,074
Posts

Drives: E92 M3
Join Date: Nov 2011
Location: Perth

iTrader: (0)

Any progress on this?
Appreciate 0
      10-16-2018, 11:17 AM   #9
bvrider1
Captain
341
Rep
787
Posts

Drives: e90 m3 + f80 zcp
Join Date: May 2016
Location: 3rdCoast

iTrader: (4)

What yr did BMW decide to change the routing for the AC belt? Just wondering if the yr of that motor is correct?
Appreciate 0
      10-16-2018, 08:29 PM   #10
aussiem3
Colonel
aussiem3's Avatar
Australia
270
Rep
2,663
Posts

Drives: Goggomobil
Join Date: Jul 2007
Location: Kangaroo land

iTrader: (1)

Garage List
Quote:
Originally Posted by perth1 View Post
Hi again,

That's all the photos for now. I have also trial fitted the M3 subframe into the E90 shell, it fits, but I need to install the fuel and brake lines before the subframe and engine can bolt in to its new home.

Today I took out the old fuel tank of the E90. I found several Redback spiders under there. Can't say I like working next to them, but I sprayed or squashed all I could see, so hopefully fewer of them next time I go under there.

Cheers,
Hats off to an epic challenge at hand! Good luck and keep us posted.
__________________
F86 X6///
Appreciate 0
      10-20-2018, 06:31 AM   #11
perth1
Private
31
Rep
79
Posts

Drives: E90
Join Date: Aug 2016
Location: Perth, Western Australia

iTrader: (0)

Hi again,
the engine is year 2012, so that photo above is how the drive belt is routed on these last ones.

Yes I've been working on it every weekend the last few months. I finally got the engine started about a month ago. At first it was running rough, so I took the injectors out and sent them for cleaning, perhaps they had been sitting too many years, but it turned out the problem was only air in the fuel line. Also I found that I had plugged in one of the plugs on one coil only half way, so it wasn't getting a spark on that cylinder. Simple fix. Now it's running.

I have transferred the M3 wiring harness and all modules into the E90. I patched in the rear door wiring from the old E90 harness into the E92 M3 harness. That went well. No errors in relation to that, and it locks all doors. Only thing is that the rear windows doesn't move yet. Apparently the rear windows are run by the power distribution box, so I probably need to code that module as E90 instead of E92 in order to make the rear windows work.

I knew the engine and drivetrain had low km since it was only 6 months old at the time of the crash, but last month when I put in the battery and powered it up for the first time I found that the engine and drivetrain has only done 11.500km since new.

I'm hoping to take it to Pedders for wheel alignment in about a weeks time if I can find time to fit the last few parts on the front end. (Only remaining to put on the headlights and front bumper). After that I need to take it somewhere for programming the ABS module since that is a replacement one from Ebay. (original ABS was crushed in the crashed parts donor car). After that I need to fill up the R134 in the AC system. And after that I need to have the TAKATA steering wheel bag replaced with a new one, since mine is of the recall type.
Cheers,
Appreciate 1
TimMc44.00
      10-20-2018, 08:33 PM   #12
JJH
Major
JJH's Avatar
Australia
535
Rep
1,105
Posts

Drives: IB E92 M3 DCT; SG E90 325i
Join Date: Nov 2012
Location: Canberra, Australia

iTrader: (1)

Thanks for the update - great work and sounds like it's all been fairly routine, small hiccups aside ....
__________________
Appreciate 0
      10-20-2018, 09:05 PM   #13
MJBO
Major
MJBO's Avatar
Australia
2496
Rep
1,442
Posts

Drives: 2023 G81 M3 Touring
Join Date: May 2012
Location: Melbourne, Australia

iTrader: (0)

Garage List
Great work you’re doing, though I won’t lie I was disappointed when I read you considered and abandoned an E91 build with it, that would have been so awesome.

Hope it all continues to go well!
Appreciate 0
      10-20-2018, 10:39 PM   #14
perth1
Private
31
Rep
79
Posts

Drives: E90
Join Date: Aug 2016
Location: Perth, Western Australia

iTrader: (0)

Hi, yes looking back at it, was silly not to spend another 8K or so for an E91. However would be easy enough in a couple of years to swap it over into a wagon shell. I also bought another half burnt E90 M3 for parts, so can use that suspension and rear guards to do a second build into an E91, but for now need some months of NO car build :-)
Appreciate 0
      10-27-2018, 02:04 PM   #15
perth1
Private
31
Rep
79
Posts

Drives: E90
Join Date: Aug 2016
Location: Perth, Western Australia

iTrader: (0)

Hi,
Some recent photos:
DIY paint:


Side of car:
Appreciate 0
      10-27-2018, 02:07 PM   #16
perth1
Private
31
Rep
79
Posts

Drives: E90
Join Date: Aug 2016
Location: Perth, Western Australia

iTrader: (0)





engine bay


Cheers,
Appreciate 1
IanMan382.50
      11-27-2018, 10:26 AM   #17
perth1
Private
31
Rep
79
Posts

Drives: E90
Join Date: Aug 2016
Location: Perth, Western Australia

iTrader: (0)

Hi again,
I've had my car in driveable condition for a little while now, and it is going well, feels like a new car. I haven't had as much as a lose bolt wrong with it so far, so I'm pleased with that. I will try to get some new photos soon. Needs a good wash first..

The independent BMW workshop in Subiaco put gas in the Aircon system for me, and bled the brakes properly.
I programmed the DSC module myself using the BimmerGeeks ProTool phone app.

I had Takata airbag recall done last week at the dealer in Wangara.

Rear windows still not going up/down, but I have a second hand JBBF module on its way from over east, so I should have that sorted next week. (Missing relays in the E92 type JBBF, so I'm getting one from an E90 with all the relays fitted).

My navigation map is the original one from 2012, so will try to have that updated soon.

Cheers,
Appreciate 1
      12-05-2018, 06:38 AM   #18
chewy7
Private
chewy7's Avatar
14
Rep
59
Posts

Drives: e91 oil burner
Join Date: Feb 2011
Location: Brisbane, AUS.

iTrader: (0)

Garage List
2010 BMW e91 320d  [0.00]
2011 BMW M3  [0.00]
1994 BMW M3  [0.00]
2007 BMW X5  [0.00]
Great thread mate ! Love what you've done !
Appreciate 0
      12-05-2018, 08:17 AM   #19
IanMan
First Lieutenant
IanMan's Avatar
383
Rep
369
Posts

Drives: Alpine White M3 Sedan
Join Date: Nov 2016
Location: Midwest

iTrader: (0)

This project makes me so happy. A lot of people in the US don't realize how fortunate we are to have our cars so readily available compared to people in your country or in Europe. We don't have to deal with all of the insane overtaxation or import fees.

I followed a similar build by a guy in Greece a few years ago. He said with taxes it was something like $90K USD + (he might have ever said $150K USD) to own an E90 M3 in his country. Long story short. He completed his build and was happy as could be.

Kudos to you and I can't wait to see more progress!
__________________
Quote:
Originally Posted by DRLane View Post
You seem like a joy...... Cheers!
Appreciate 0
      12-09-2018, 12:41 PM   #20
perth1
Private
31
Rep
79
Posts

Drives: E90
Join Date: Aug 2016
Location: Perth, Western Australia

iTrader: (0)

Thanks guys,
Genuine E90/92/93 M3s are quite available in Australia. They used to be expensive, but the last 2-3 years the prices have come down a lot.

It would have made more sense to do a replica build in other countries where M3s are not available or have import tax, but I've had fun along the way anyway. However I probably wouldn't have started it now with the current low prices on the real M3s ;-)

I started this with an impulse buy of the wreck back in 2013, so I spent $$$$$ on the parts donor when it was only 6 months old. I had it in storage without doing much at all to it (other than collecting parts) until about 2 years ago. Then I found the nearly free E90-shell and slowly have done everything DIY.

Here is a photo taken today.



So, its almost complete. I will be spraying more clear coat on some panels to fix some of the imperfections. And I'm still missing a few parts.

Cheers,

Last edited by perth1; 12-09-2018 at 12:53 PM.. Reason: photo
Appreciate 2
TimMc44.00
XKxRome0ox1587.50
Post Reply

Bookmarks

Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off



All times are GMT -5. The time now is 03:43 AM.




m3post
Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2024, vBulletin Solutions Inc.
1Addicts.com, BIMMERPOST.com, E90Post.com, F30Post.com, M3Post.com, ZPost.com, 5Post.com, 6Post.com, 7Post.com, XBimmers.com logo and trademark are properties of BIMMERPOST