E30Rossi's Full Build - Overhaul - 5 Lug - Bay Shave - M54 Swap (Pic Heavy)

[E30Rossi]

After years of doing research, following build threads for hours, and lurking around here, it's time for my contribution!

I will post my build progress from day one, in February 2018 until now while i'm currently doing an engine bay shave and M54B30 swap!

I figured this was the perfect place to document everything I've done to date on the car since I get so many questions and comments on IG (@e30rossi)

Current Build/Mod List:

Engine:

M54B30 from 03 E46 330i
Full Refresh (Piston Rings, Bearings, Gaskets, Timing, Seals)
All new sensors, coilpacks, Vanos rebuild
M50 Intake Manifold
Port matched head
Bimmertune TB Adapter
Mishimoto Intake Elbow w/ K&N Filter
RallyRoad ICV Fitting + Hoses
SAP Delete
ECSTuning Aluminum Waterpump + Power Steering Pulleys
Custom shortened Oil Pan, Pickup Tube
VACMotorsports Oil Pan Baffle
Wideest 24V Swap Engine Mount Arms
Revshift Poly Engine Mounts
Refurb Alternator
New Power Steering Pump

Body/Exterior:

Complete Rust repair / coating
New BMW Roundels
Smoked Fogs/Reflectors/Turn Signals
Antenna Delete
Euro Front Grilles
20% Tint All Around
Shaved and Repainted Engine Bay

Suspension:

BCRacing Coilovers (5 Lug) - 8k Front 10k Rear
SRSConcept Front Lollipops - Caster Correcting
Garagistic Weld-on Rear Camber Adjustment
Diff Mount Reinforcements
Rear Swaybar Mount Reinforcements
Trailing arm reinforcements
Trailing arm mount reinforcements
Rear shock mount reinforcements
Front Balljoint Reinforcements
Front Engine Mount Reinforcements
Front Swaybar Mount Reinforcements
Garagistic Rear Subframe Poly 95A Bushings
Garagistic Rear Trailing Arm Poly 95A Bushings
Garagistic Rear Tie-Downs
Powdercoated LCAs - New Balljoints
21mm ST Front Swaybar - Poly Bushings - Strut-mount Adjustable Endlinks
New Rear Swaybar Links
UltraRacing Rear Strutbar
Garagistic Front Strutbar

Brakes:

Front E36 Spindles
New Front/Rear Wheel Bearings
Front/Rear E46 Calipers - Fully rebuilt / powdercoated
Stoptech Street Pads
Garagistic Front Stainless Brake Hoses
ChaseBays Rear Stainless Brake Hoses
New Hardlines Front to Rear
ABS Delete

Wheels/Tires:

BMW Style 32 Wheels (17x8 +20, 17x9 +26)
Kumho Ecsta PS51 Tires (205/40 215/40)
MotorsportHardware Extended Studs
MotorsportHardware Forged Lug Nuts
OEM Style 32 Spare Wheel

Steering:

OEM Z3 Steering Rack
Garagistic Rack Swap Kit
New inner/outer tie-rods
CondorSpeedShop Steering Linkage

Drivetrain/Shifter:

ZF320 Transmission
Garagistic Poly Trans Mounts
Garagistic Rear Differential Poly 95A Bushing
2.93 Differential
Garagistic Tall Chassis Mount Shifter
Garagistic DSSR
Revshift 24V Swap Poly Giubo

Exhaust:

Full 2.5" Stainless Custom Exhaust with V-Bands /Pie-cuts from VillainzWelding
Vibrant ultra-quiet resonator
Vibrant streetpower muffler
Active Autowerke E46 Catless Headers

Interior:

Steering Wheel Adapter
Nardi Vintage wood steering wheel
BMW Horn Button
Replica Recaro Seats - Black "Leather"
Custom powdercoated seat brackets
Rear OEM Leather Bench seat
Rockford Fosgate 5.25" Front Component Speakers
Rockford Fosgate 5.25" Rear Speakers
Pioneer USB/Bluetooth Headunit
SRSConcept Accelerator Pedal Bracket
Painted Carpet - Trunk included
CATuned Black Motorsport Floor mats
Kilmat Sound Deadening - Entire Car Front to Back

[CubbyChowder]

Dang, I think a lot of the pics aren't loading, at least for me. Looks like an awesome build from what I can tell though!

[E30Rossi]

Dang, I think a lot of the pics aren't loading, at least for me. Looks like an awesome build from what I can tell though!

I'm new to this so not sure if i did something wrong! But thanks 🙏🏻 gotta find the rest of my pictures to continue 🙏🏻

[Northern]

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First test fit of the wheels

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Fitment looks like it will be perfect!

The working pics look like the top line, and the broken ones look like the bottom. Almost like they didn't upload or something?

If I go to your profile and click the Media tab, only the pictures that work in this thread show up.


Followed you on ig for a few years now I think. Always impressed with how you consistently get such good pictures of your car.

[Sledgehammer_01]

Nice work and nice nugget

[E30Rossi]

The working pics look like the top line, and the broken ones look like the bottom. Almost like they didn't upload or something?

If I go to your profile and click the Media tab, only the pictures that work in this thread show up.


Followed you on ig for a few years now I think. Always impressed with how you consistently get such good pictures of your car.

Thanks for that, ill check out what happened when I get home later! i appreciate the kind words 😇 I love combining my two hobbies together !

[E30Rossi]

Nice work and nice nugget

🫡🫡 thank you! I will try to update this thread as I go on with my current progress

[Sledgehammer_01]

Please do, build threads are great for sharing ideas for others to consider.

However I think the biggest aspect that is not considered is how much of value it is for the owner of the project. I have a continual build thread that's now 33 pages long for my 93 land cruiser that I started back in 2014. Its fun and fulfilling to look back through the thread at the progress and pictures. Just like flipping through a photobook on you coffee table, scrolling through each photo brings back the feeling and emotions of that time in my life. It can seem like a chore at times to stop in the middle of a task and snap a pict then create a detailed post on here but its important.

I recently saved my whole build thread because I wanted to protect my journey through time with my Land Cruiser in the event the hosting site went down. And that driving motivation is the same reason I started my build thread on my e30 Touring here.

So keep it up and do it for you, you will the happy you did!

[E30Rossi]

Sorry guys, my first time making a thread here and most of the pics didn't seem to work so i'm starting over from here!



The day I brought her home - Drove it from Toronto to Montreal with no issues besides a little fuel leak, which I figured out why later on



Was super excited for my first major project car



Waiting to get inspected and plated - Didn't feel bad about leaving it outside based on the condition of the car


Horrible ripped up seats covered with seat covers - Gotta change ASAP


First thing on the list, some maintenance since who knows when the last time anything was done

[E30Rossi]

This was a must



Scored these replica seats for super cheap from a friend, so went with these for now, with hopes of one day getting some Recaro Classic LX with fishnet headrests



MUCH better


Heard this was one of the best first mods, scored the rack for free so let's try it out!


Rack swap

[E30Rossi]

Ebay orders coming in, fixing up some small details



Refreshed the front end with some paint and installed smoked turn signals and reflectors


Scored some OEM leather bench seats on a roadtrip in Toronto again


First of many Garagistic orders - Rack Swap Kit, Antenna Delete, Shifter bushing kit


Small details starting to show

[E30Rossi]

Size comparison with the Daily


Quick compound / polish did wonders on this!



Alignment done after steering rack swap!



One of my first photoshoots with it in it's stock form

[E30Rossi]

SmallDrove the first summer the way she sits and enjoyed it thoroughly but always knew I wanted to refresh it!

Proceeded to store it the next winter ( Canadian winter lasts 5-6 months) and started piling up parts for the full refresh coming next !



This thing brought so many smiles everywhere I went



everyone goes crazy for pop-outs


Scored some yellow fogs for next season


Also found Euro Grilles and had to jump on it!

[E30Rossi]

First time we ever got vanity plates in Quebec, had the jump on the opportunity! SR is my initials and also my photography brand @photography_sr for automotive photography!



Since I bought the car, the diff was always leaking, and there was a few knocks in the suspension
At some point during the first winter storage, I decided to remove the diff to address the leak
This led very quickly to pulling the entire rear subframe to refresh it after one look at it...
This led to the "While i'm here" addiction which never ended until today

After the first summer driving it, I stored it for winter which ended up staying there the following year since I know at this point a full rebuild had to be done


First things first, Got rid of entire AC system, compressor was seized


Rusty leaky diff and first look underneath

[E30Rossi]

Sad looking engine bay



Didn't want to touch this part because I knew i'd get here one day, which is where i'm at now (2023)


Begin removing things


Couldn't possibly put this back in looking like this.. which caused me to take a year off to collect parts




Gross...