zackpl
Part of things
Posts: 68
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Thanks! Passenger side rear sill section, rear beam mounting point and rear wheel arch has been repaired. No more welding under the floor then as all affected areas are done. No pics showing the process but it was similar as on previous post. Repaired inner sill first then reconstructed jacking point inside the sill, welded outer sill on place and repaired inner rear arch. Pics showing finished repair. As there is no need to weld the floors I could fit the carpet back on. Had to clean it first as it was stained and dirty. Took two days in the present weather to dry off (with the help of a heater). Carpet back in the cabin Cleaned all the carpet sections with Auto Finnese all purpose cleaner. Good product btw, you can control its strengths by mixing it with water in a different ratios. Wipe it all with a damp cloth and vacuumed using old good Henry. Next I glued A post sections to the body and fitted center console. Found some burned out bulbs on the heater panel and inside the ash tray so replaced them with new bulbs. Cleaned the vinyl/plastic trim as well. The rear bench and shelf also are back in the cabin. These were washed/cleaned the same way as the carpet. Found factory label from 1983 with car equipment codes under the rear seat. Kick panel under steering column also is back on place cleaned and all connected. Then I found power windows don’t work, didn’t test them after fitting center console. Mirrors and central locking was working, no clicking etc so I had no power in the power window circuit. I checked the fuses they were all good. I had to strip the kick panel I installed just a few minutes earlier to reach power windows relay. I checked for voltage in the socket after removing the relay and null, no power there, how? I inspected the socket and found positive wire has somehow pulled itself back so no wonder I had no power here. Checking the wire alone was positive showing 12v so with a relief I pushed it back firmly to the socket. I cleaned front seats as well but will install them after adjusting hand brake cables. At this stage interior is much cleaner, brighter and smelling nice.
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Last Edit: Jan 9, 2019 11:03:56 GMT by zackpl
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Top marks! Great repair work, good to see it going back together.
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Sierra - here we go again! He has an illness, it's not his fault.
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Some great work here! Love seeing the colour of the interior transform, proper satisfying!
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zackpl
Part of things
Posts: 68
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I had some time with my welder spent recently to repair rear wheel arch sections. Original ones were rusty in places and after cleaning some previous repairs to the body were revealed, thankfully only to small area. Perforated rust and a patch of bond exposed on the right rear wheel arch. Section cut out and welded in. Welds were grinded down. The inner part of wheel housings on both sides weren’t that bad and after cleaning were covered in epoxy primer. Then for extra protection covered in seam sealer from the gun. It was time to pour some anti rust wax in all the cavities. I’ve used Noxudol wax from Auson, good product solvent free so no nasty smells inside the cabin. Whole lengths of sills and rear wheel arches were injected with this stuff. Rear wheel housings were cleaned with wire brush by hand and all repaired areas painted previously in zinc reach primer covered in polyurethane paint. All this prior for last stage of rust proofing - application of Noxudol 1600 body schutz like product. It has long drying time so I have to wait till all will set. In the meantime the rear beam was disassembled, old bushings pressed out. Trailing arms and beam were derusted mechanically, decontaminated and covered in Hydrate 80 from BH. Then fat coat of epoxy primer was applied along with polyurethane paint. New bushings were installed as well, polyurethane ones. New parts are being delivered to overhaul suspension for both axles. New shocks, new top mounts, new rubber seals for springs, dust protection covers and buffers, new wishbones, control arms and steering and arb links. Also new differential mount as old one was damaged. Hopefully all will be installed soon and car will touch the ground on its wheels!
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Last Edit: Feb 28, 2019 1:30:08 GMT by zackpl
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Marc
Posted a lot
Posts: 1,037
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Love to see an E28 getting some love. I had an M535i manual and a 528i with an M5 engine swap. Lovely old things, wish I hadn't sold either of them.
Looking forward to progress on this one!
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zackpl
Part of things
Posts: 68
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Used to have an M535i but with auto gearbox, these engines transform under manual drivetrain definitely. They feel too lazy when connected to automatic gearbox. Suspension legs have been assembled with new components and a set of KAW lowering springs. Rear beam and suspension is back Fronts will have to wait till the wheel housing are covered in Noxudol 1600. I turned my attention to the engine. I changed rocker cover gasket, inlet manifold gaskets and trimming chain cover gaskets. Engine was covered in old baked oil and road dirt so cleaned it all. Also changed all rubber pipes. Rocker cover and thermostat housing along with other smaller bits were decontaminated and painted in silver. Painted areas were covered in high temperature resistant clear coat. Connected the loom previously cleaned as well and fired the engine to check if everything behaving as it should. No surprises here so all good. Some body work also have started already thanks to my brother. Next I’m going to fit prop shaft and finally land the car on some wheels.
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zackpl
Part of things
Posts: 68
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Still working on this project with massive progress yeah! Changed rear brake discs and pads also refreshed front brake calipers by cleaning them and painting in gold. I’m a wheel whore, I like deep dish wheels from the 90’s, mainly of German origin. I’m planning to run this car on a set of staggered Remotec A wheels 8x16 and 9x16 but will try these first: set of staggered Brock B1’s with 10J wide rears. I know the ride comfort will be ruined but this is not going to be driven daily so why not? Repainted them by myself in gunmetal grey metallic. The most important part of the body arrived finally! The whole front section with nose panel, straight from Germany for the cost of £440. So I had to carefully remove the original panel which was previously damaged and repaired so poorly it let the water to trap and obviously rotten the whole connection lines between front inner wheel arches. Old panel removed, pics showing affected areas: Before removal of old panel I took measurements from across towers and hood latches on both side. Then had to cut and weld new steel pieces connecting with the new front panel. Shelve on left hand side was repaired the other side shelve for a battery was cleaned and rust proofed. Then it was time to test fit new front wings, front grilles and the hood with new panel tacked in places. All looked good so I welded the front panel to the body. Tested again to make sure everything is where it should be and prepared the repaired areas and new panel for painting. Sprayed epoxy primer first then filling primer, base colour and closed everything spraying two layers of clear coat. I’ve used Max Mayer 0200 which gave nice depth and gloss but I’m not fully happy with it as the gloss and depth should be better, anyway I had to use the whole can so painted lower valance panel. So the front was fully assembled with lights, grilles, kidneys and front indicators. Adjusted the hood and front wings as well. I decided too get rid of original hood as it was in terrible condition and sourced another one in much better nick but in silver. In the meantime I sold my beloved BMW E34 525i Sport. I owned this car since 2012, every mile driven in this was fantastic but as a daily it wasn’t a good choice of cheap motoring. It was sold on a set of Brocks I refreshed earlier. Back to lapis. It took some time to prep it, plenty of abranet sanding again thanks to help of my brother it went smooth and shortly it was sprayed in primer. We decided to keep the roof as it is it’s in fantastic condition with no rust, dents, etc it will be machines polished only. After a few days when smoothing the primer was completed it was painted in 173 Lapis blue colour and as a clear we used Max Mayer 0300. This clear has the depth and gloss I wanted! Just a few contaminations to remove by polishing the clear coat. New paint job looks fantastic, really like this flat blue. It suits the chrome trim so nice. Just rear door shuts on the sill parts left to do and it will be assembling time!
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Last Edit: Jul 8, 2019 20:30:53 GMT by zackpl
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Looking awesome. BMW has some of the best blues out there and Lapisblau is one of my favorites. This car will be a credit to you and the great work you've done.
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Cool car, nice work you're doing. Presumably, much of this is upside-down welding? Not easy, yours looks great. Best, John
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Great work. Lots of good info on this thread. I've always had a soft spot for the E28 and considered buying one a few times. Looking forward to seeing this one back together.
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zackpl
Part of things
Posts: 68
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Jul 11, 2019 21:05:34 GMT
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I have removed all masking and started putting parts back. Bonnet and petrol flap went on, repainted air box with new Pipercross filter was mounted, screen wash jets connected, door locks and ugly looking side mirrors as well. Bought these to complete under bonnet look: 3 piece set of soundproofing mats. And on the car: Also fitted boot seal with a help of budeprhane glue. Left the boot shut for good bonding, should be ok by tomorrow. Turned my attention to interior next as it was very dusty after painting. Two runs with Henry were needed. Door cards will be washed/cleaned at later course. The most ugliest BMW steering wheel which is in this car is going to be ditched and Mtech 1 steering wheel fitted. It took me a long time to find a one. This is pre facelift car with old type spline so finding nice steering wheel is very hard or very expensive if you’re in the rush. Took this pic showing repaired sill / wheel arch section. curse word lighting and angle but the details are spot on. Wings mirror refreshed and side moulding trims installed. Other side is awaiting for new mounting clips to arrive the same with door handles. So close to the moment it will roll its wheels on tarmac again but as for now still levitating
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Last Edit: Jul 11, 2019 21:06:09 GMT by zackpl
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Jul 11, 2019 21:47:00 GMT
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I can't wait to see this on those rims. I had a lapis blue 520i a lot of years ago. Bought at the same time as a Benz W123 200t. Kept the Benz and sold the Bim.
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zackpl
Part of things
Posts: 68
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Jul 11, 2019 22:29:47 GMT
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Jul 11, 2019 22:57:30 GMT
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Just read through that thread, zackpl. Your work is top notch. I'm gonna follow this BM thread with interest.
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Stunning !! This is going to be beautiful whhen it's finished, Looking forward to seeing the wheels.
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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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Jul 12, 2019 12:39:44 GMT
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100% no, sorry 200% awesome. Great car. I used to have this same model years ago. First one was a 525i followed by a 528i. Both great cars
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zackpl
Part of things
Posts: 68
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Jul 13, 2019 10:29:06 GMT
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Thanks guys! This parcel arrived yesterday, inside new Bowden cable with the handle, door trim clips, handles and rubber plugs. Exhaust bracket mounted to the gearbox and new badges. I’ve painted plastic covers covering towing hooks. Degreased first, than sprayed in plastic primer and finally painted in acrylic black. New badges, mud guards inside the wings went on. Car is almost complete, just bumpers left to fit. I’m planning to fit stainless steel exhaust from manifold to the end. This should be ready for road use then! My son doesn’t like the steering wheel as well so the change was approved!
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wc
Part of things
Posts: 45
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Jul 13, 2019 22:52:10 GMT
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Nice car! Lovely colour.
Makes me feel guilty about my e28 M535i... I parked in the back corner of my shed about 12 years ago as it needed some minor rust repairs and mainly because the clutch master cylinder failed... it is now buried under a mountain of stuff and really needs rescuing!!
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zackpl
Part of things
Posts: 68
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Jul 21, 2019 10:25:04 GMT
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Yes it’s a very nice colour, quite distinctive well suit the chrome work and factory brown tinted glass. The car finally landed on a set of temporary wheels - BBS Mahle. And fiirst drive! After 10 months of standing on the set of mobile axle stands Lapis drove out of the garage for a gentle wash. When it has dried off I drove it back inside for polishing action. I’m very happy with the drive, it runs sweet, suspension is firm and nice, no unwanted noises apart it’s running with exhaust manifold only. It’s booked in in my local exhaust shop for a full stainless steel system this Thursday. Stay tuned!
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Last Edit: Aug 29, 2021 18:17:17 GMT by zackpl
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Jul 21, 2019 12:07:59 GMT
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Looks stunning that does.
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