In June 2005 I needed a project to keep my mind and hands busy for a year or so during the evenings and weekends. A friend of mine found a crusty touring in CT that needed a year or so worth of work. The pictures you see is my first attempt at refurbishing a 2000tii. I had help on the project from the wife and both sons.

Here is what I have accomplished so far.
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To answer some questions:

Body shop, Romans 8:36 is in Greensboro, NC. Contact number is (336) 931-5596.

Eric Kerman did the motor EDK40@aol.com
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I will add pictures to this post via the edit feature so check back for updates.


Evan, my youngest, drove to CT to pick up the car


I drove the car all summer in this condition, had some fun in it


The car appeared solid but ugly


The wife says it looks like a rusty Vega


Motor in sad shape but all the numbers match


Rear subframe was solid but years of moil (mud and oil)




Interior was ok, but hard and brittle. The car mostly lived in the islands and Florida


all of the touring tidbits were in the hatch


In October, I put the car in the air on the "poor boy lift" to tear it down


Poor boy lift



It was ugly


I have seen worse, I think


Dropped the motor and front subframe together


Some help from young son


Help from soldier son when he was on leave last Thanksgiving


Stripped the tii parts from the motor



Transferred the shell from the "poor boy lift" to a dolly using the Egyptian method, rollers


Evan wondering either 1. Is that Dad's head we left on the dash of the car? or 2. Will he ever get this pile of parts back together?


Evan and I pushed the car on the dolly up the road in front of the house and loaded it into the hauler on a side street for a trip to the body shop.


Evan used his big Dodge Cummins Diesel to take the shell from MD to NC to the body shop


While the car is at the shop, I worked on the components


Replated Euro headlight buckets


Out of eight wheels that came with the car, only five are useable


Trued, straightened and painted


3.45:1 LSD diff was tired and not LSDing, CV boots also tired after 30 some years


When I cracked the diff, there were two spun bearings and a chip from the gear. New bearings, seals and gear set


Refreshed half shafts


Thirty years of neglect, alot of fun though by the POs


Good for another 30 years



Front suspension pieces were worn too



I hope I got it back together correctly


Bilstein HDs ready to go


Old steering shaft


Stripped cleaned and painted


Motor rebuilt and waiting



Can't wait to fire it




Rear quarters had to go


New metal


Always hiding somewhere



Donors were found and installed


Rusty kink removed and patched


Rusty kink due to bad seals


New Mike Pelley floorpan


Seam sealer all around












Have you seen this color before?



I think that fresh motor will look quite nice in there






All of the leading is complete around the rear hatch. Legend has it, Bauer built the touring from the B pillar back, leading the seams around the hatch




Final prime on 13 June. Color may go on 17 June








POR was used as a sealer in places were rust visits, ICI (PPG) primer, ICI color and World of Color clear is on the car. There are four coats of clear that will end up to be 2 or 2 1/2 once the final sanding and buffing is completed. The body shop says World of Color clear seems to be the most clear out there and has the same UV protectants. The Wurth chip guard product was used in the wheel houses and the bottom of the car. He also sprayed the chip guard around the lip of the rear fender well openings. That part of the car that suffers chips that are often seen.


The pedal box was shot but surprisingly, the frame rail is solid


Surface rust on the bracket and booster



I could not find paint the color of that green BMW used so I reverted to black.


This is the fun part, dropping off a bucket of moily parts and a week later and $50, you pick up these. The sorting is really fun, suffered all kinds of fun from the wife. They understand, but they like to "Mimster" us. Mimster is a word some of use to honor a lady that really likes to tease her husband about his 02 addiction

Here are some interior tidbits


These parts are touched up with SEM Landau Black




Found all of this Netherlands money in the dash



Refurbished the heater box following the FAQ to the T





















Trim going on (August 26, 2006)




Dash recovered by Just Dashes in California


Leaving the body shop, Romans 8:36 in Greesboro, NC owned by Greg Rogers He thinks this is over 200 2002s he has done body work on in his 30 years of doing body work. His first touring.


Headed for the hauler


Tucked safely into the hauler in 100 degree heat, and 90 percent humidity.


The carpet, dash and most of the glass is in.




That love it or hate it hatch rear end. Let the new rust begin.


Greg Rogers, the body man telling me something about the work he did.


Dang, I guess I have to provide the motor? Duchess, my car dog, is in the corner of the shot.


Vapor barrier installed with Dum Dum



Nathan and I looking it over


Ruth driving her touring to the shed, sitting on a stool and I acting as the pusher and brakeman. Glad no cars came while we were moving it


Just Dashes refurbished the dash, grain very close to the original


Seats recovered in original Mobil Tradition fabric






Last edited by BillWilliams on 8-9-06 04:50; edited 82 times in total