So here goes, the build story of my BMW E30 350i!
Many years ago I wanted to build my perfect E30. Even though that is probably not possible, I had a clear idea of what it should look like. This is what I had in mind:
- Powertrain: naturally aspirated v8 and manual gearbox
- Outside: sleeper look, only with Alpina front spoiler and 15 inch wheels
- Inside: standard looking interior, but with M3 cluster and Alpina gauges
- No trick suspension, just a simple and well set-up spring and damper combination
- Some performance upgrades, like powerflex bushes and a big brake kit
- Clean looking engine bay
- Power assisted brakes
- Basically a turn-key car > start and drive (like a daily or weekend car)
Then it was time to get to work and source parts…
It all started with a very nice 320i from 1984. One owner from new and no rust. We picked it up in Berlin and drove it home directly. Even though the power plant in this car was still in excellent condition, I decided to use this car for the engine swap:
The engine should be the S62B50 from the E39 M5. We looked for engines on the internet, but finally found a wrecked M5 with a running engine. This should be the one.
We picked the donor car up on an evening in the winter and even though it was smashed on both sides, we were able to test drive it a bit. The engine felt good and so did the gearbox. So on the trailer and off we went!
Front struts, rear subframe and trailing arms were removed and powder coated:
Only new parts are used and I had decided to give it the sleeper look. Therefore I kept the 4 lugs (stud conversion) and went for 15 inch wheels. To keep the power in check, I wanted the biggest brakes possible that would fit into the 15 inch BMW nuova S3 wheels (TYP 1209-A & TYP 1270-A). I ended up with Wilwood Midilite 4 piston calipers with 310mm rotors. We use these as well on our track-car and they work great (with B-compound brake pads)! Note: 10mm spacers are needed…
Springs and dampers are new (Koni Sport and G&M springs by Sandtler) and on the important areas, powerflex bushes are used. As said, I could have gone for an adjustable coilover set, but wanted to keep it simple. A turn-key car that does what it is meant to do: start and drive. This set-up should be a good compromise between sporty and still comfortable.
With the complete new suspension, dampers, brakes and bushes, this was the result:
I ordered a custom made radiator from Pro Alloy in the UK:
The motormanagement has been reprogrammed by Tino Trümer. All features are taken out (EWS, CAN bus link to DSC, Servotronic and ZKE) and the factory provided Alpha-N function is activated. The map is optimized and the sport-function from the M5 is switched on continuously to give better throttle response:
As I did not have the time, the knowledge and the skills to finalise the project, I asked Ronny Dreizehner to finish my project. He agreed, but mentioned that I should arrange the exhaust system. After some searching, I found GD Performance in the Netherlands and they are making beautiful custom systems. This is the result from their work:
When this was done, I brought the car to Germany where Ronny could do his magic:
Here are some pictures from all the details. Wilwood master cylinder:
The radiator sits in the front area just behind the grill. Therefore the hood lock mechanism had to be moved next to the headlights:
Hard brakelines on the front strut to reduce the movement of the flexible part:
We moved the brake booster to the trunk to create a clean look under the hood (and improve weight distribution):
Ronny Dreizehner created custom airboxes left and right for a symmetrical appearance which I wanted:
As mentioned, the radiator sits “in” the frame behind the grill. Ronny also added cooling for engine oil and power steering fluid:
I actually moved away from the “finned” diff cover from the Z3 M coupe and went for a standard E36 diff cover with 2 mounting points for more rigidity:
Originally I also wanted to have Wilwood calipers in the rear, but mounting was difficult and this would be with un-vented Z1 brake disks (290×12). Ronny talked sense into me and we ordered a nice set from 300mm.de: vented 294×19 rotors with 540i/750i calipers:
Airbox finished and painted with wrinkle finish:
Engine bay painted and heat-shield/damper material applied:
Engine finally back in again with everything connected:
So when everything was put together, this is how it looked like!!!
First time on its wheels with everything on it, including the Alpina front spoiler. I love it with the 15 inch alpina look wheels!
Ronny and his team did a great job to finalise all the basics for the car. The brakes work as they should with a nicely assisted, OEM feel and firm pedal. The engine runs great and the manual gearbox shifts as it is supposed to do. The Alpina vent gauges are installed as well as the 320iS tacho: that means an original look with the correct information at hand (oil temperature, diff temperature, etc.). So the only thing left to do was to pick-up the car in Germany. Of course there will be a list of things-to-do, but that will be part of the finetuning, where I can take time to get all the details right. And perfecting can only be done by testing and driving the car, so that is what I will be looking forward to for the coming time! And when the time is there, pictures of the interior will follow as well…
Here are some final pics from the pick-up and at home:
Thanks for reading! If you have any questions or remarks, please send me a message. I am always open for suggestions or any new thoughts!
-Hendrik
Specifications:
Drivetrain
Engine: BMW S62B50
Motormanagement by Tino Trümer (Alpha-N, optimized engine mapping)
Exhaust: custom system from GD Performance in the Netherlands (Guus and Don) – Equal lenghth headers with only rear silencers
Gearbox: BMW 6 speed manual from the E39 M5 (Getrag type 226 / BMW S6S 420G)
Differential: Medium case type 188 differential S2,93 (25% LSD) with E36 diff cover (custom mounts)
Driveshaft: front end from E39 525d and rear end from e36 328i (?) – custom made with new center bearing
Cooling: custom radiator by Pro Alloy Motorsport (UK) with SPAL electrical fan
Brakes
FRONT: Wilwood 4 piston forged calipers (Midilite) with 310x21mm vented disks
REAR: E34 540i calipers with 294x19mm vented disks
Brakelines made from Cunifer + Goodridge flexible steel brake lines front and rear
Brakebooster in the trunk (E39 M5)
Interior
BMW E30 320iS Tacho with coding chip to correct rpm signal and 8.000/min redline
Alpina digital vent gauge for temperature (oil and diff) and pressure (oil and intake)
BMW E28 sportseats (Blue cloth; 0130 Pacific Blue Herringbone) with E30 consoles
M Technic 1 steering wheel (385mm)
Suspension
Koni Dampers (front: 86 2277SP1 / rear: 80 2522SP1)
Sandtler spring kit (60/60 non-adjustable)
BMW E30 M3 front control arms (aluminium)
Powerflex Rear Beam Mounting Bushes
Powerflex Rear Trailing Arm Bushes
Powerflex Front Lower Wishbone Rear Caster Offset Bushes
H&R Anti-roll Bars front and rear (22mm front and 18mm rear)
Others
Custom shift mechanism (shortened E30 shifter arm)
Custom airboxes by Ronny Dreizehner
Bosch 044 fuelpump (PN# 0 580 254 044)
Remote oil filter housing with thermostat (BAT-Motorsport) and additional oil-cooler
Power steering fluid radiator
Wheels: BMW Nuova S3 (7Jx15 ET12 & 8Jx15 ET12)
Tires: Michelin Pilot Sport Cup 205/50 ZR15 – To be tested which tires are best…
BMW E46 steering Rack (yellow tag ZF rack with PN# 7852 974 712) – ratio 13,7:1
Alpina frontspoiler Typ 137 (PN# 41 00 145)
Alpina footrest (PN# 51 00 114)
M Technic 1 rear spoiler (PN# 1 923 965)
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Wheelmen 