For a long-time BMW enthusiast and seasoned track day participant, the thrill of racing is addictive. After years of enjoying track days in various BMW models, including an E36 328i, a ’95 M3, and an E46 M3, the desire for more intense competition led to a return to rallying. The plan? To transform a beloved 2002 BMW M3 into a rally-spec machine ready for the Empire State Performance Rally, the challenging New England Hill Climb series, and potentially even the legendary Targa Newfoundland. This is the journey of converting a track-proven BMW M3 into a versatile rally and hill climb competitor, focusing on the key components and modifications.
Before diving into the build, let’s appreciate the starting point. This E46 M3, finished in Imola Red over black leather, boasts a sunroof-delete configuration and manual heated seats. With just over 80,000 miles, it was intentionally acquired and rigorously maintained as a dedicated track car. Its history includes conquering corners at iconic tracks like Sears Point, Thunderhill, and Mosport.
The transformation began with stripping the interior to prepare for essential safety and performance upgrades. The first delivery of performance parts included crucial components for driver and co-driver safety and control:
- Momo racing seats and mounts: These provide essential lateral support and keep the driver securely planted during aggressive maneuvers.
- Momo steering wheel and hub: A performance steering wheel offers improved grip and feedback, critical for rally and hill climb precision.
- Macht Schnell seat bases: These bases ensure a solid and adjustable foundation for the racing seats.
- PTG driver’s floor pan: Enhancing driver ergonomics and foot support in a racing environment.
Further enhancing safety and functionality, the next set of parts focused on occupant restraint and co-driver support:
- OMP harnesses: Multi-point harnesses are paramount for driver and co-driver safety in rally conditions, providing secure restraint in the event of impacts or rollovers.
- Spare wheel tie down: Securing the spare wheel is crucial in rally racing where tire changes are common.
- Carbon fiber co-driver’s foot rest: Providing the co-driver with a stable and comfortable foot rest improves navigation and communication during demanding stages.
With the interior gutted, the installation of these components began. The dashboard was temporarily removed to streamline wiring and declutter the interior. After cleaning up unnecessary wiring, the dash was reinstalled, creating a clean and focused cockpit.
The new racing seat and steering wheel were then fitted, instantly transforming the driving environment. The significant weight reduction from stripping the interior was immediately noticeable in the car’s higher ride height.
A critical element for rally and hill climb safety is a robust roll cage. For this build, Bill Doyle of Cage This was chosen for his expertise and reasonable pricing. His experience as a BMW rallyist himself, owning both an E30 and a 318ti rally car, ensured a cage built to the specific demands of rallying. The custom cage fabrication process was meticulously documented, showcasing the precision and craftsmanship involved.
The final roll cage installation not only provides essential structural reinforcement and occupant protection but also integrates seamlessly with the vehicle’s chassis, enhancing overall rigidity.
Post-cage installation and with seats and harnesses in place, the transformed M3 underwent a shakedown at New Hampshire Motor Speedway. This track day served as a crucial test to evaluate the initial modifications and identify any necessary adjustments.
Interestingly, the weight reduction from the interior was somewhat offset by the addition of the roll cage’s steel structure, indicating a trade-off between weight and safety.
To optimize the dashboard for racing, the space previously occupied by the double-din navigation stereo was repurposed into a custom gauge panel. The original faceplate was adapted, and a carbon fiber sheet was cut and epoxied to create a lightweight and functional gauge mounting solution.
Fire safety is paramount in rally cars. A 10BC fire extinguisher was strategically mounted to the transmission tunnel, utilizing the handbrake bolts for easy access and secure placement.
The co-driver’s footrest installation presented a minor challenge due to the uneven floor in the E46 M3. Cleverly, the original passenger airbag bracket was adapted with slight modifications to provide a level mounting point for the footrest.
Finally, Sparco drink bags were added to the seatbacks. These hydration systems, similar to CamelBaks, are easily attached to racing seats and feature extended drink tubes for convenient hydration during races.
This initial phase of the BMW E46 M3 rally car conversion showcases the foundational steps in building a competitive and safe vehicle for rally and hill climb events. The focus on safety components like the roll cage, racing seats, and harnesses, combined with performance enhancements like the steering wheel and gauge panel, lays the groundwork for further modifications and the exciting journey ahead in motorsports competition.
