E46 Coupe Race Car Ground Up Rebuild

When the first lockdown was announced and we all had to work from home we decided to use this time to replace our E46 330 Race car.

The car had been used for 3 years across multiple series and picked up a couple of battle scars. The car was overdue a refresh and as Tom was working from his personnel garage bodywork and paint was not really an option. Tom however, is a fabricator with a very active imagination.

We started by getting the shell dropped off and fully stripping the low millage 318Ci shell to inspect the shell and start the prep work. It was obvious that the shell was one of the better ones and would make a great base, partially because the N43B20 engine ( Now skipped) coated every inch of the car in oil. Not great for a MOT but great for preserving the body shell.

We then wasted no time a unbolting everything from the car so we could inspect the chassis.

The Car was fitted to a spit and rotated around to reveal minimal rust but a tick layer of oil dirt and grim. This was soon removed to reveal a near perfect shell.

The Boot floor was cleaned and checked for cracks, non were present as i suspect the 143hp powertrain was not enough to rip or tear anything. Re-inforcment plates from reddish motorsport were fitted to future proof the shell.

The boot floor was cut out to allow for a flat floor later and allow easy access to the rear subframe and arms.

This is the point where we decided that lockdown was in for the long haul. We used this time to remove all the seam sealer and full seam welded every seam inside and out on the car.

We then decided that with all the prep and fabrication that has one in to to the car a little more wont harm, so the only thing left to do was a side exit. This was done a little different to most. We cut a large oval through the sill and then welded back in a tube to give the sill the ultimate strength. Keeping the car as rigid as possible.

The underside was then treated with Dinitrol RC900 rust converter then Dinitrol 4941 black corrosion protection for that factory finish. Dinitrol ML was then used in all cavity's preserving the car for the future.

Before the interior goes for paint all the all parts that mount through the shell must be fitted now so there is no need to drill or cut any of the painted interior.

The was then sent away to OCD Refinishing in Leeds to get the interior painted in BMW mineral grey.

The next step was to build a robust and future proof fueling system a bimmerworld twin pump set up feeding an Alloy Racing Fabrications 2 Ltr swirl pot. This will be enough fuel to support an future expansion including forced induction.

We built a box to cover the fuel components ensuring that the car complies with all Motorsport regulations.

A 3Kg Zero 360 lifeline fire extinguisher was then fitted with nozzles in the engine bay and the driver compartment.

A large Varley red top battery was then fitted to the car, the extra 3kg was deemed to be worth the piece of mind and reliability of a larger more stable battery, ensuring all injectors and management have the correct power needed.

The dash board was then re fitted into the car and cut as close as possible to the cage. All ducting, sound deadening and the lower gear stick surround was removed to save weight.

The dash will be covered with alcantara when the interior design in complete but this will be one of the last jobs to avoid damage.

The two relays and bulk of the custom interior loom will be routed behind the air bag hatch in the dashboard.

A 7" ECU Masters ADU was mocked up on a steel bracket, this will be moved during the final stages of the car as it sites too close to the wheel but this allows the car to go to Matt at Level motorsport for a bespoke chassis loom.

A PMU solid state distribution box was fitted to the transmission tunnel, this will remove all but 2 relays in the car and all fuses. Simplifying all electrical circuits and minimising future issues

A Can keypad that is fully programable with multi push buttons, this will simplify the controls and allow future expansion

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The final form (for now)

After nearly year of been put on the backburner in favour other projects our E46 330 race car is now complete and currently been tested. Testing and programming has absorbed all our spare time but all looks promising with the final MK60 Bosch ABS faults found and fixed (one speed senso pinned backwards). The car has a custom Mill spec chassis harness including ABS and all lights, wipers ECT beautifully crafted my Matt at level motorsport. This is no mean feat, although it's a race car it has everything required to be road legal as well as provides additional fuel pumps, analogue and digital sensors and boost solenoids, for when 240 hp isn't enough.

The chassis have been built with the future in mind and has everything required to accommodate more power than it will ever be allowed to race with (300hp/tonne cap).

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