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klodkrawler05
klodkrawler05 HalfDork
2/20/25 9:54 a.m.

After a 5 year hiatus to do some adulting (start a family) the stars aligned and I've begun another e46 project. I sold off my previous time attack e46 during the winter of 2020: Build Thread I've missed that car over the years, but my priorities in life have shifted. Lap times take less of a priority, being able to share cars with my boys, and getting more use out of a car that I've poured hours/dollars than the occasional track event all take priority. So with that in mind I'm setting out to build a dual purpose car. It won't be as fast as a dedicated track car, and it won't be as comfortable as a bone stock wagon.

Rewinding the clock 8 months, we moved from MI to AZ for work, which gave me the opportunity to shop all the rust free offerings down here. I found a basic non sport package, automatic 325i wagon. I was specifically looking for an LCI model with the MK60 ABS (more to come on that)

The first step of wagon ownership for me is always a Costco run to make sure it can wagon as expected. Mission successful.

Shortly after that I started hunting for a few parts to make some incremental improvements. Junkyard hunting lead to a set of sport seats and leather door cards to replace the peeling door panels and non sport seats the car came with. I also scored some aero roof bars off a volvo suv that happened to fit the profile of the e46 bars pretty well:

I also found a set of Apex ARC8's in nearly the right fitment.

Confirmed bike hauler capability. 

3 months into ownership a listing on marketplace popped up for an M3. reading between the lines of the listing the car was either a basket case, a scam, or the deal of the year. IMO it proved to be the 3rd option. So this 2005 1-owner, 107k mile, all original factory 6spd manual M3 came home with me, for hardly more money than people ask for a clean automatic e46 wagon.

I considered for a little while whether I really wanted to tear apart a car this nice as a swap donor, but ultimately decided the low miles and maintence history was exactly what would make this a great swap donor.

So I drove the M3 and Wagon for a little while as I started to formulate the plan and acquire parts. Eventually the pile got big enough that I thought it was time to start the project. These are my only 2 cars so the goal was to perform the swap about as quickly as I could, while using my gravel bike as my primary mode of transportation. 

The highlights of the parts pile:

MCS 2 way coilovers with dual use appropriate spring rates

WPC coated rod bearings

Euro knockoff headers with OEM euro cats to remain emissions compliant

E82 6 piston brake calipers to use with M3 sized rotors

E82 fitment 17x9 Apex Arc8's to account for the extra width the M3 suspension will add

it's been a constant battle of scope creep, but I finally have enough progress that I thought it made sense to start a build thread. I plan to provide a few more posts over the next couple days to get the last 3 months of work caught up.

AngryCorvair (Forum Supporter)
AngryCorvair (Forum Supporter) MegaDork
2/20/25 10:27 a.m.

Soooo many ragtop M3s were automatics. Cool that you found a three-pedal donor.

brandonsmash
brandonsmash HalfDork
2/20/25 10:27 a.m.

Hey, you're in my neck of the woods! Welcome! Let me know if you need fab space; I enjoy sharing my workshop(s) so people can build stuff and am in the east valley.

 

klodkrawler05
klodkrawler05 HalfDork
2/20/25 10:32 a.m.

While I was initially looking for a donor I wasn't being picky about manual vs SMG, however after getting knee deep in the swap I'm glad I found a native manual, clips, bits of wiring, the hydraulics etc were all ready to be harvested vs tracking down separately. 

 

Brandonsmash, I'll definitely be in touch once the car is moving! there's a couple tasks I want to tackle that I don't have the tools/space for in my garage.

brandonsmash
brandonsmash HalfDork
2/20/25 10:44 a.m.

I've been fortunate enough to collect some pretty damn nice tools at my home shop and I'm a fan of sharing them. I just added a CNC press brake. That was maybe a stupid impulse purchase, but oh well. 

How are you finding Chandler so far? 

 

Slippery
Slippery UltimaDork
2/20/25 10:56 a.m.

Love this!!

Mattk
Mattk New Reader
2/20/25 11:09 a.m.

This is awesome, I love it!

klodkrawler05
klodkrawler05 HalfDork
2/20/25 11:16 a.m.
brandonsmash said:

I've been fortunate enough to collect some pretty damn nice tools at my home shop and I'm a fan of sharing them. I just added a CNC press brake. That was maybe a stupid impulse purchase, but oh well. 

How are you finding Chandler so far? 

 

Hot! we moved here 4th of July weekend. Although it's hard to complain about the weather right now while I'm working on the car in shorts and my family at home shovels snow. Also, having lived in the country for most of my life, it's been a pretty great experience having tool/auto stores located blocks away instead of 20-30 minutes. 

And despite being in a non HOA neighborhood I've managed to already receive one warning from the city for leaving an engine sitting on a tire outside my garage overnight. Lesson learned, the neighbors aren't car guys cheeky

dyintorace
dyintorace UltimaDork
2/20/25 11:25 a.m.

I've always wanted an e46 wagon with an S54! I've had e46 wagons, e46 ZHPs and e46 M3s but never a sedan or wagon with an S54!

brandonsmash
brandonsmash HalfDork
2/20/25 11:49 a.m.

In reply to klodkrawler05 :

Oof, you moved here last summer? Ouch. It was the hottest on record, breaking 2023's record. I bet this summer is even worse: The winter has been so mild (as in, nonexistent) that I suspect the summer will be absolutely grueling. 

Do you do any track or autocross driving at all? 

 

klodkrawler05
klodkrawler05 HalfDork
2/20/25 2:29 p.m.
brandonsmash said:

In reply to klodkrawler05 :

Oof, you moved here last summer? Ouch. It was the hottest on record, breaking 2023's record. I bet this summer is even worse: The winter has been so mild (as in, nonexistent) that I suspect the summer will be absolutely grueling. 

Do you do any track or autocross driving at all? 

 

I am not comforted by the thought of a 3rd record breaking summer in a row, although that'll give me even more of an excuse to make some trips into the mountains this coming summer once the car is road trip worthy!

In a past life (before kids) I was the WMR-SCCA solo chair and participated in some Gridlife/Optima events. but I quit pretty cold turkey and aside from bumming a co-drive a at the local track autocross a couple times I haven't been on track at all. 

docwyte
docwyte UltimaDork
2/20/25 3:38 p.m.

Watching this with great interest!!  I've also always wanted an S54 E46 6MT wagon

Paris Van Gorder
Paris Van Gorder Associate editor
2/20/25 4:16 p.m.

I am thoroughly invested in this thread. It's so cool to see how you are merging different aspects of your life with the car.

SpeedAddict502
SpeedAddict502 New Reader
2/20/25 6:53 p.m.

Are you on E46Fanatics?  I sold my full E46 M3 swapped wagon a year or two ago on BAT but still have my full M3 swapped E91 wagon.  And I grabbed another E46 wagon a few months ago in the perfect spec, so that one will be swapped soon.

Awesome stuff!

dyintorace
dyintorace UltimaDork
2/20/25 6:54 p.m.

In reply to SpeedAddict502 :

What motor did you put in the e91?

Jesse Ransom
Jesse Ransom MegaDork
2/20/25 7:03 p.m.

That's such a good looking car. I tend toward even older stuff, but I think the E46 is staggeringly better-looking than the E36, and is still a more handsome car than the later stuff.

Currently BMW-wagon shopping, but for my wife's DD, so I will have to envy the awesomeness of your path as we stick to something more pedestrian.

Lof8 - Andy
Lof8 - Andy UltraDork
2/20/25 7:10 p.m.

S54 wagon is rad!   I'm in.  

SpeedAddict502
SpeedAddict502 New Reader
2/20/25 7:14 p.m.

In reply to dyintorace :

Its a full M3 swap on the E91, so the S65 with a manual transmission.  Imported a sunroof delete roof for it too lol.

When I do these swaps everything from the M3 gets moved to the wagon shell.

klodkrawler05
klodkrawler05 HalfDork
2/20/25 9:18 p.m.
SpeedAddict502 said:

Are you on E46Fanatics?  I sold my full E46 M3 swapped wagon a year or two ago on BAT but still have my full M3 swapped E91 wagon.  And I grabbed another E46 wagon a few months ago in the perfect spec, so that one will be swapped soon.

Awesome stuff!

I've spent a ton of time over the last 8 months in the touring section stalking swaps, but haven't actually started a thread over there yet! 

dyintorace
dyintorace UltimaDork
2/20/25 9:20 p.m.
SpeedAddict502 said:

In reply to dyintorace :

Its a full M3 swap on the E91, so the S65 with a manual transmission.  Imported a sunroof delete roof for it too lol.

When I do these swaps everything from the M3 gets moved to the wagon shell.

I had an e90 M3 as well. The thought of an e91 M3 has me salivating!

klodkrawler05
klodkrawler05 HalfDork
2/20/25 9:33 p.m.

Alright! Tuesday November 13 thru Sunday November 17 update: At this point of the project I was feeling pretty confident that all my research would pay off and I had the majority of parts I needed to get this swap done in pretty quick order.

I got out of work Tuesday and felt pretty motivated, so hover mode engaged on the wagon: 

I had some extra help on Tuesday which I was very thankful for, although it slowed progress ever so slightly:

Got most of the auxiliary stuff removed Tuesday but didn't want to get stuck with the garage open overnight. Wednesday I actually hooked up the cherry picker and got the engine/trans out! (later than expected)

Since it was getting pretty late I decided to just set the engine on a tire in front of the garage door, I listed the drivetrain for free on marketplace just to get it out of my hair and assumed it'd be gone quick. 

I would later learn (when a notice arrived in the mail weeks later) that my neighbors had taken a photo of the engine during the 14 hours it sat in the driveway and sent it into the township who issued me a warning about storing car parts outside.cheeky

I had to wait until the weekend for the next part of the swap as I wanted to be as minimally annoying to the neighbors as I could and our sloped driveway made this task impossible to do there

Saturday evening saw the drivetrain out of the car, I put the front bumper and lights back on the car and set it back on the ground after this so that it looked like a full car to passers by overnight:

Sunday I got an early start, pulled both front/rear subframes, suspension, brakes out of the m3 and swapped the ones from the wagon into their place. Here's a photo mid process on the front suspension:

I ended Sunday with the M3 back to a rolling chassis with non M suspension/brakes underneath it and the S54 sitting beside the wagon with the M3 subframes stored underneath the wagon.

At this point I was feeling pretty good that my 1-2 month estimate was plenty safe and the swap was going to be exactly as easy/smooth as the internet made it seem.

xflowgolf (Forum Supporter)
xflowgolf (Forum Supporter) SuperDork
2/20/25 9:55 p.m.

Disassembling a car in the street after the overnight driveway engine complaint is rather hilarious.  

klodkrawler05
klodkrawler05 HalfDork
2/20/25 10:36 p.m.

In reply to xflowgolf (Forum Supporter) :

I actually wasn't aware of the complaint yet at this point, it took a couple weeks before the warning with a photo of the stock m54 motor arrived in the mail 

docwyte
docwyte UltimaDork
2/21/25 11:15 a.m.

In reply to SpeedAddict502 :

Do you have the BaT link for your E46 wagon?  Curious to see the pics and what it went for

docwyte
docwyte UltimaDork
2/21/25 11:17 a.m.

In reply to klodkrawler05 :

Would've been kinda funny if you'd put the wagon drivetrain into the M3 convertible...

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