Thanks for the comments guys. A bit of time as passed since my last post but the project has been progressing over winter.
Suspension Cont...I made a mistake with the first front struts I fabricated. I basically made the strut tube too short from an error in measuring somewhere. In full compression the wheels would foul the upper chassis before the shock absorber would run out of travel. And therefore they were too short in full droop as well. But the strut bodies were salvageable so after putting it off for a while I started again and remade the strut jig as well as I though of a much easier way to do it.
The tube in the right side of the picture is the same size as the sleeve nut at the top of a Bilstein inset so this aligns the geometry.

I used a spare hub/spindle for the other end of the jig and welded on some guides to set the alignment of the tube.

I have made a template for drilling/cutting the weld on bits so it is now a reasonably easy process to make the struts.
E46 Front WishbonesI am using E46 lower arms to increase the track width by ~27mm each side. They fit with no major modifications but beware the Meyle wishbones don't fit as they have a larger outer ball joint that fouls the brake disk. Lemforder ones are close but fine.

I have used Powerflex E46 (60mm) bushes to fit the original compact lollipops. The wishbones needed a small amount of fettling.

And the Z3 (2.7 turns) steering rack to finish it off.
Top mountsI made a drawing and had a pair of top mounts machined. The spherical bearing is eccentric by 27mm to match the increased track width. Therefore the camber remains the same nominally. I will adjust the camber with shims on the hubs/spindles.

It's tight but I can get a socket in from the top to tighten the top sleeve nut. I may need to grind down a special socket to make life easier. I have also double skinned the strut tops on the inside. I cut the tops out of the donor 328 Estate.


Rear SuspensionAs I explained earlier in the post I am using Escort Gp4 type Bilstein coilvers on the rear. The photos below show how I have modified the mounting point to move the top mount 18mm outboard so the spring clears the arch. The underside plate is only tacked in at present.

A 4.45 LSD from LithuaniaI sourced the medium case LSD and a 4.45 crown wheel and pinion set from the ebay seller
az_autoshop in Lithuania. The guy was really helpful and it arrived quite quickly. He seems to stock quite a few spares and I would recommend using him. The casing was pretty poor with rust as they often are but I had it sand blasted and it came up well. I have modified the LSD to take four plates by having the end cap machined (~5mm) and removing the spacer washer. I have retained all the belleville washers. I completed the build with new bearings and seals as well.

Checking the break away torque.

Setting the pinion preload.

Checking the backlash.

I am going for the twin ear back plate as well.
