BMW E36 M3 Project - Project Car

Project M3 is near completion. Notice new UUC big brakes behind UUC D-Force wheels

It's been a while since we've updated you with progress on our E36 M3, but that doesn't mean we've been idle. In pt12 (et 11/09) we saw a dramatic increase to top-end performance with BimmerWorld's Sunbelt cam kit and software, coupled with an AA track pipe that deleted the cats. And we're happy to report after several thousand miles that we haven't had any issues.

There was a slight drop in torque from the cams and M50 manifold combo, so we found the perfect upgrade from Bavarian Autosport to restore most of it.

Shorty
BavAuto sells coated "shorty" headers that are a direct factory replacement. We took them to our friends at Modified by KC for the straightforward installation - although one nut (out of 24) behind the OBD2 air pipes took 30min alone!

After several hours and busted knuckles, the M3 sounded unchanged at idle. But on the road I couldn't believe how good the bottom-end felt. On the dyno, this was confirmed with a whopping increase of 16.1whp and 22.6 lb-ft at 3750rpm. Not anticipating any gains up top, we were pleasantly surprised with 4.7whp at 6800rpm.

These gains compliment the cam kit perfectly. And with more than 260whp, the M3's performance is virtually seamless.

Bavarian Autosport's "shorty" exhuast headers gave surprisingly good power gains
Bav Auto headers installed by Modified By KC. Reaching all 24 nuts isn't easy but take your time!
Bav Auto headers installed by Modified By KC. Reaching all 24 nuts isn't easy but take you
To bring some peace after the track pipe install, we added a Remus cat-back exhaust system

Exhaust
For this test we ran a baseline dyno with a new Remus cat-back exhaust from Bavarian Autosport. It has twin 90mm titanium tips that look killer. It uses 2'' tubing throughout, which isn't as big as our previous 2.25'' UUC RSC36 system. As a result, it tested about 4whp down on the UUC unit.

For street use, the Remus exhaust would be our choice with the AA cat-delete track pipe, simply because the UUC cat-back was just too loud with the track pipe.

UUC tests its exhausts as a cat-back replacement, tuning for the best sound and power. But lose the cats and the noise is too loud. With the Remus alternative, we didn't gain much power over a stock exhaust but it's lighter than the factory unit, looks good and is nearly as quiet.

But if we ever hit the track or strip, the UUC unit will find its way back on again for maximum performance.

With around 60whp gains over a stock M3 at 7000rpm, Project M3 is now significantly faster. In fact, we're seeing quarter mile times in the mid/upper 13s, with trap speeds around 104mph - on par with the E46 M3. This brings us to our next upgrade: stronger brakes.

Remus uses 90mm titanium tips
Power: With 16whp and 22 lb-ft over the stock exhaust manifolds (blue), the Bav Auto headers (red) were 0.2sec quicker from 3000-5000rpm on the dyno (2.5 vs 2.3sec). They restored the lost torque from the M50 manifold and cam kit. Compared to stock (black), our M3 is much quicker, reaching 7000rpm in the time it used to take to hit 6500rpm
Power: With 16whp and 22 lb-ft over the stock exhaust manifolds (blue), the Bav Auto heade
Torque from a naturally aspirated engine is limited by displacement. So the idea is to sustain high RPM torque so it converts to more power. And while we've only got 12 lb-ft more peak torque over a stock M3, we have gains of up to 37 lb-ft near redline (equating to 46whp). So acceleration from 4000-6500rpm is 0.6sec quicker (3.41 vs. 2.81sec)
Torque from a naturally aspirated engine is limited by displacement. So the idea is to sus

Brakes
UUC released a budget-priced big-brake system that uses Wilwood/UUC four-piston calipers, pads of your choice (we used Hawk Sport), Motul DOT4 fluid, steel braided lines (six) and optional factory E46 M3 two-piece, drilled, floating rotors. It should be the perfect upgrade for a street car that sees occasional track time, as well as full-blown race cars; the difference being the pad compounds.

In fact, UUC developed the kit on its own racecars in SCCA ProSolo, BMWCCA and NASA events, and posted several victories.

With brackets manufactured in-house, UUC's ensured a perfect fit, needing no spacers inside our UUC-supplied D-Force wheels. They also fit in our SSR wheels.

The combined weight savings is 9 lb per side. Being unsprung weight, some of which is rotating weight, it's a significant improvement to overall performance.

UUC also has a rear system for the E36, but since ours is a street car, we kept it simple: we contacted Bav Auto to order its Cool Blue pads, drilled rear rotors and Noise Free lube.

Once everything was installed, we bedded-in the components with a series of hard stops from 80-10mph. Whether it was the 30°F weather or the pads themselves, it took a while to get the system to feel the way it should. The pedal was hard but the response didn't wake up until a few hundred miles later, after which the feel has been incredible.

Besides of the feel, the brakes look great and really stand out. To compliment the front we bought $15 high-temp caliper paint from an auto parts store and painted the rear calipers, which has held up surprisingly well.

UUC big-brake kit was developed with Wilwood. It includes four-piston calipers, adapter brackets, drilled E46 M3 rotors, Hawk pads and stainless lines
UUC big-brake kit was developed with Wilwood. It includes four-piston calipers, adapter br
We opted for the two-piece floating M3 rotors for better heat management. We gained 0.4" over stock but lost 9 lb per side
We opted for the two-piece floating M3 rotors for better heat management. We gained 0.4" o
UUC bracket ensures caliper clamps edge of rotor for better leverage