scotto
Part of things
Posts: 44 
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Hi Guys, I've been meaning to sign up for a while, so here goes... I've hankered after one for a long time and had promised myself once i was in my own house i would treat myself. As you can imagine the house choice almost certainly revolved around the garage space available  we hit it lucky and almost as soon as we were in i started looking, perhaps not the best time to nigh on skint myself but with the prices on the up it seemed like it was now or never! The brief was quite open, any colour, round or square, standard or modified but the body/shell had to be very good, I'm fine mechanically (relatively speaking!) but bodywork scares me. I wasnt even bothered about body style initially and nearly went for a touring project but then in my head my perfect 2002 vision wasnt a touring. I had nearly sorted a deal for a very nice standard sahara beige 2002 that is/was on here but through the sellers holidays etc the sale dragged on and whilst i was on a 4 hour round trip parts run for said car i received a PM on here offering me the car that i ended up buying. It had a restored body and a nice list of parts, during the resto it had had a colour change and turbo arches/ airdam, this car was already 'ruined' to the purists and i had always intended to modify the car and do euro drives/ track it. The Sahara beige example was original and perhaps too nice to 'ruin' and i ashamedly decided to back out of the sale (sorry Andy). The car i bought was located with James at JFI and long story short i ended up buying it minus an engine or gearbox fitted (a tii bottom end and e12 head included as well as a 235/5 gearbox). The car was 5 hours away so the better half and I set off at 3.15am one Saturday morning in respect that James was to open up especially for me to view the car, the journey was great and we arrived an hour early:  The car was as expected and it was great to meet James, a deal was struck with the owner in the back ground and i returned with a friend a month later to bring it 5 hours up north, this journey wasnt so great as the transporter broke down 80 miles into the drive and we had to stop overnight in Barnsley and bodge the drive belt in the morning to complete the other 450 miles or so! Pic's at JFI and just before departure home:       Tucked up back in its new home around 6 hours later:  If you’re still reading then well done! Ill update the rest below Thanks, Scott |
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Last Edit: Dec 1, 2017 12:47:58 GMT by scotto
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scotto
Part of things
Posts: 44
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When we picked it up the bottom end was sat in on its mounts, the head was in the boot along with the gearbox as well as a host of random parts/ nuts and bolts. First job for me was to get the bottom end out and onto an engine stand, whilst it was a rebuilt bottom end and hadn’t covered many miles it looked to have been sat a little while and I’ve always wanted to build my own engine. As the head was already off I decided to strip the rest down and rebuild it. I’m lucky in this sense as I’ve helped out at a competition engine builders for the last 14 years or so, my boss that runs it is oldskool and a wealth of knowledge on a whole host of marques, especially bmw. It’s a small ‘man in shed’ type machine shop but a lot of well-known companies get engines built by him and his son, his cylinder heads/ engines perform unbelievably well in a lot of cases. Engine stripped and packaged off for me to take in:      Crank was checked and polished, clear to see that it’s had some trauma in a past life with the amount of grinding it’s had previously. This was a cause for concern at one point as I was going to run 144mm rods and some custom pistons with a higher compression ratio however something else has taken up that allocation of that money so I’m sticking with the bottom end as it is for now (more on that later). The pistons in the block measured up well and in great condition so a simple hone was all that was in order:    Whilst the bottom end is staying standard i’m still going to have the head modified, to accompany this we’ve spec’d a camshaft for it and to match this I’ve selected the mildly uprated Schrick single springs and KM Cams steel rockers. Standard valves will remain for this iteration of the engine. Along with this I’ve got all new rocker shafts and hardware, some random pictures:    The car also needed a clutch, I thought I’d future proof and go for the Helix Autosport one along with a steel billet lightweight flywheel. In total, including the clutch, there’s 3kg’s saved here. Not too much for what will primarily be a road car but enough that it should make a nice difference to performance in the lower down gears. I’m still waiting for the shorter 22mm arp flywheel bolts to come in so we can balance the bottom assembly.     Scott |
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scotto
Part of things
Posts: 44
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Once I had the car up on axle stands I could have a better look underneath, all new to me as I’ve never looked under a 2002 before! The shell is like new, the sub-frames powder coated and complemented with new bushes (some look like black powerflex items) and new kunifer/ braided lines ran throughout. However the rear driveshaft boots had split and chucked moly grease everywhere and the diff looked like it had been sat at the bottom of a river, along with the state of the driveshafts:      This led me to refurbish the driveshafts and after checking that the diff plates weren’t worn I had the cover off and refurbished that and gave the case a lick of paint:      The driveshaft bolts were loose/random/ rounded off so I ordered all new hardware to mount them again, new crush seals and LSD oil. The spacers for the e21 diff that had been used appeared to be old stub axles with the stub’s cut off, this in my eyes is a bodge and they are also rather weighty. Tom on here was luckily selling some Jaymic aluminium ones:  Pictures all back together:    Whilst on the subject of the transmission, the gearbox was reported to have a slight crunch from 3rd down into 2nd when driving spiritedly. Being that the car will be driven spiritedly a lot we thought we’d get the box apart to inspect it. I was nervous about this, any reports available on the internet makes it seem like it’s nigh on impossible, luckily my good friend helping me with this build is more confident and competent at this sort of thing. Results were not good, corrosion on gears 1-5, 1-4 needing replacement, 5 is useable. 4 out of 5 baulk syncro rings also needed replacement. As you can imagine these 235/5 gearboxes are quite rare and parts are expensive for them if you can even find them. The following pictures are where the piston/ rod fund has gone, I'm still awaiting the baulk rings before it can go back together:        We and the specialist who supplied the spares are under the impression this box was built with knackered gears to sell on, I feel sorry for the owner previous to me who probably paid an arm and a leg for this box. All bearings appeared new and the casing restored and other than the knackered gears/ syncro’s, it is a gem. My dream ’02 has always had a dogleg box in it so I can forgive this expensive development in the project. Thanks, Scott |
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scotto
Part of things
Posts: 44
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Small update, all my bearings, gaskets, piston rings etc are all at the engine builders I help out at. Just waiting on the 22mm arp flywheel bolts and the bottom end can get balanced and it can go together. I'm hoping my head will be started on soon too! My fuel tank has also been vapour blasted, had come out very well, just needs the fuel return welding in and I can have that painted and will refit it and plumb it all in.   Also bonded new spring platforms in for the fronts and wired the springs in. Also got hold of another wirelock bolt that was missing so could finish that off. Just bearing grease to get hold of and the front struts can go back in!  Thanks, Scott |
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scotto
Part of things
Posts: 44
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Feels like I’ve spent quite a lot of time on this but don’t feel all that much further forward! I guess I’m almost back to where I started when I got the car except everything mechanical is now done properly and there’s also lots more shiny bits! The main focus recently has been building the bottom end back up whilst I wait for the head to be modified. The gearbox is still in bits, thinking being I can use the input shaft to set the clutch on the flywheel so the gearbox will probably be one of the next installments! I got the block back from where I help out at on weekends sometimes (read Saturday job of 14 years!), great job as I knew. Even though its spent hours in the chemical hot wash I can’t stress the need and importance of an immaculately clean block. I spent hours further cleaning all the oil galleries and mating/ bearing surfaces. New compression seals, o-rings, gaskets etc throughout. Following this I painted it in satin black and started the bottom end build.   Before and after as an example on big end:   Piston:   I set about balancing all the static items since all rotating items had been done. This took me around 6 hours, one piston was 8g heavier than the rest and that’s a fair chunk to take out of a piston, it wasn’t balanced very well as it was. In the end I got the rods perfect and the piston assemblies to within 0.4g, rather stringent for a basic build but when your own time isn’t costing money it was worth it! My board of scribbles:  Job done:  Next was for ring gapping and building each assembly up, all spot on out of the packet so no need to change. I did check every single one though and took the corners off, something many people forget to do:    Crank in and torqued, turns nicely so that was a relief!  New Keyway:  Pistons in:   E21 oil pump rebuilt and shimmed with 2002 pick up pipe, new pulley and locking tab installed:   Chain and guides on:  Front cover, water pump, crank pulley etc all fitted as well as that lovely flywheel:    Then time for the baffled sump that my dad kindly painted for me, also has oil temp boss in it with m22 to 1/8 NPT reducer:   In line with the car patiently waiting:  Next update will hopefully be with the boot finished up and fuel tank in properly then onto the gearbox build! Thanks for reading, Scott |
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scotto
Part of things
Posts: 44
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A little more progress for anyone interested. I mentioned previously my dad had painted my sump for me, I also had my fuel tank soda blasted so he kindly painted that for me too. I had a boss welded in for the fuel return as my car came with a carb tank instead of the Tii one. With the fuel fitting in the boss it sits a little proud but it’s not too much a cause for concern. I also snapped the pipe on the old fuel pick-up/ sender unit so I bought a repaired one from Brian on here (Regalo) and James (Jamesnutter50) who I bought the car from kindly sent me a spare that he had, much appreciated both. I fitted that with a new o-ring and installed some heat reflective tape I had for where the rear silencer gets rather close to the tank.    I bought some sticky back foam tank lining from wallothnesch and installed that. Because the tank is a carb one, the securing holes are different for 3 out of the 5 holes so I had to rivnut these but now the tank is properly secured. Also bought a new rubber filler neck/ gaske arrangement and a lockable petrol cap. Tank in:      I need to get some smaller bolts but the longer ones did a great job of installing the tank with the foam at its original height, without risk of me stripping threads etc. Now the foam is compressed ill just swap the bolts over with shorter ones, 1 by 1. To finish the install at the rear I need those shorter bolts and a 6mm to 8mm fuel hose connector and a small length of 6mm hose and I can get all the hose clips on and tightened up. The hard line to the front is already in, as is the return. I’m also going to carpet the small section of the boot at the rear that is body colour, underneath the swirl pot arrangement but I need my new battery/ battery bracket to show up before I can do that. I also popped into my friends garage (A Local German specialist that builds/ looks after/ repairs some high quality cars, mainly 911’s) to borrow a slim 30mm socket so I could torque up the crank pulley nut, the new pulley with integrated trigger wheel wouldn’t allow the socket I have inside! My friend also helped with the initial stripping of my gearbox so whilst in there I grabbed my input shaft so I could fit my clutch. Pics below:    That’s about it for now, hopefully we’ll get the gearbox back together at some point soon and my cylinder head might get started… |
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scotto
Part of things
Posts: 44
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My battery, cage and m6 female to post mount adapters arrived yesterday and it was a rare night where I was able to spend it in the garage! Box of contents that showed up at work:  Thought I’d weight the new and old and was pleasantly surprised, I knew the old one was a big old beast but not this heavy! So overall a nice 12kg saving.   Bit of a mock up:  Some drilling, Riv-nutting later (lots of sweating, drilling into the thing makes me stupidly anxious!) and amateur carpeting later:   I’d bought a big roll of automotive felt backed carpet off ebay along with two cans of carpet glue. It was my first experience of carpet glue so I’ll treat it with a little more respect next time, that stuff is STICKY! Sometime next year when ill hopefully have a cage in ill use the rest to carpet out the rear. I also bought a 3/4 pressed plate off ebay and got that on. I’ve got the full size one for MOT’s but with that fitted it blocks off the vent in the airdam and I think this is where I’ll fit my oil cooler when I get around to ordering one.    Thanks for reading, Scott |
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Awesome car and nice work so far. Bookmarked!
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piguin
Part of things
Posts: 136
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The car looked great in the pic up pictures, but the mechanical work you've put so far really inspires. Bookmarked, can't wait to see it finished and driven properly  |
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Bigdoors
Part of things
cherwelldoors.com
Posts: 176
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Lovely motor & a great build. Very similar to mine. Keep up the good work and updates.
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Nice car and quality build!
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scotto
Part of things
Posts: 44
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Thanks guys, appreciate the kind words so far. It's been a lot more work tha i thought so far but I'm sure it'll be worth it! Lovely motor & a great build. Very similar to mine. Keep up the good work and updates. Had a look through yours, you had a bigger job on your hands it seems. The body work was all done when i got mine thankfully! I like where yours is heading, love the b&m shifter mod you've done, was off to go and order one up to do the same but didnt realise how much they were  and I'm not normally one thats scared of spending i liked the rocker depress tool you made too, i hope ill be building my head soon but may have to loan it off you if i change my cam in future! |
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First time i see a garage with a carpet floor!You have to be very prcize to keep it clean.
Your car really rocks! Great attention to detail. I see custom trigger wheel on the crank. Standalone EFI..?
Good luck with the build.
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what a beautiful example...the work your doing certainly fits the car...top notch
JP
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I know its spelled Norman Luxury Yacht, but its pronounced Throat Wobbler Mangrove!
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Bigdoors
Part of things
cherwelldoors.com
Posts: 176
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Thanks guys, appreciate the kind words so far. It's been a lot more work tha i thought so far but I'm sure it'll be worth it! Lovely motor & a great build. Very similar to mine. Keep up the good work and updates. Had a look through yours, you had a bigger job on your hands it seems. The body work was all done when i got mine thankfully! I like where yours is heading, love the b&m shifter mod you've done, was off to go and order one up to do the same but didnt realise how much they were and I'm not normally one thats scared of spending i liked the rocker depress tool you made too, i hope ill be building my head soon but may have to loan it off you if i change my cam in future! That shifter wasn't expensive. Cheap eBay jobbie for an E46 I made fit. Was less than £20 |
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Bigdoors
Part of things
cherwelldoors.com
Posts: 176
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Bye the way if you need the depress tool just let me know.
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Bigdoors
Part of things
cherwelldoors.com
Posts: 176
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scimjim
Club Retro Rides Member
Posts: 1,503
Club RR Member Number: 8
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BMW 2002 - The Tii (ish)scimjim
@scimjim
Club Retro Rides Member 8
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One of a handful of cars that could tempt me away from my single marque ethos. Love the work (except for the appalling wire-locking ) and the 'ruined' look is exactly what I'd go for - although the engine would be much newer |
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That's stunning, love it.
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Brilliant work and a fantastic looking car
Looking forward to updates
Bookmarkex
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BMW E39 525i Sport
BMW E46 320d Sport Touring (now sold on.)
BMW E30 325 Touring (now sold on.)
BMW E30 320 Cabriolet (Project car - currently for sale.)
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we hit it lucky and almost as soon as we were in i started looking, perhaps not the best time to nigh on skint myself but with the prices on the up it seemed like it was now or never!
and I'm not normally one thats scared of spending 
