The problem is that the right front tire rubs on the strut housing. The weird thing is that the left front is fine. There is actually about 3/8 of an inch clearance on the left side. The right is completely up against the strut housing. The lip of the rim is only about 3mm away from the housing. I tried swapping tires, just to make sure that was not the issue.
I am not sure what it could be. All the front suspension components and tires are from an M3, so I don't see how they could be rubbing. There are no marks on the strut housing that would indicate that a tire ever rubbed there before. There really is not anything that can change, since this is really only one piece that we are dealing with. The spindle is connected (I assume welded) to the bottom of the strut housing, so I don't see how that angle could have changed. The only thing I can think of is that the strut housing bent somehow, but I have no idea how that could happen.
Here are some pics:
You can see the housing/spindle are basically one piece:
Measuring right side:
Measuring left side:
I am not sure if this is common, but both tires rub on the sway bar when the wheel is turned all the way:
Any thoughts? This really sucks, since otherwise, the car is ready to drive :-(