Introducing FAQ Memberships 04/17/2017I would like to introduce everyone to the FAQ memberships. A fun way to fund the site and to contribute for those who are interested. Everyone starts as a Solex Member. This membership is free and not much visible is changing (I limited the personal message storage to 150). Kugelfischer membership. As a reward for your donation of $20.02 per year, you will not see any external advertisements, the site will look cleaner and run a bit faster. You will also get a couple of BMW 2002 FAQ Stickers. Turbo Membership. As a reward for your donation of $50.02, you will not see any external advertisements, the site will look cleaner and run a bit faster. You will also get unlimited Personal Message storage, ability to create Private and Restricted Photo Albums. You will also get a couple of BMW 2002 FAQ Stickers and a Bottle Opener. Alpina Membership. As a reward for your donation of $100.02 per year, you will not see any external advertisements, the site will look cleaner and run a bit faster. You will also get unlimited Personal Message storage, ability to create Private and Restricted Photo Albums, and an ability to upload Movies to the gallery. You will also get a couple of BMW 2002 FAQ Stickers, a Bottle Opener, and discounts on our accessories at the store. There is also a fancy title that comes with each membership.
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After getting the drivers side inner sill in, I felt in a good place to start the floor pans! Here's the rear one clamped in place:
You can see there that the floor pan wouldn't quite cover all of the areas that needed to be replaced. I decided to weld in what I had and come back later with more patches. I'd like to note that on this one, I did a butt weld, which made the whole process much more difficult. It is not easy to cut things perfectly for a butt weld when there are so many curves and corners, and I ended up spending a lot more effort on it that I had expected. For the rest of the floor pans, I left a 1/4 inch overlap when cutting out the old stuff, so I could do a lap weld and that worked out much better. Here's the front floor pan welded in:
In the front footwell, you can see the immense damage around the pedal box as well as the, well, whole footwell! Heres a photo with more of the footwell cut out, as well as some initial repair attempts around the pedal box:
(also, note behind the photo the trusty Hobart Handler 140. If you need a solid body work welder I can't recommend this enough!)
After some more repairs, the front footwell looked a little bit like a frankenstein inspired piece of work. I wasn't really happy with it, since I was still getting a handle on the Hobart, and ended up coming back to tidy this up.
Also, you'll see in these photos some dangling wires and stuff. If I were to do it again, I would have removed those wires and everything else before going forward. The wires did end up being removed. Hindsight, etc. Anyways, after the floor pans and initial footwell repair, I moved on to the passenger side, which was just as bad as the drivers side. Here's the starting point:
You'll notice on the bench behind there a cup of coffee. That was a very important part of this process!
So now was the time for the same drill: inner sill, outer sill, rear floor pan front floorpan then front footwell repair. It went a little faster the second time, but I hope I never have to do it a third time! After it was all complete, there was one part that I was avoiding since I wasn't sure how to proceed- the rear subframe mounts on both sides were corroded and in need of replacement. So I ordered some subframe mounts from Wallontesch and crossed my fingers and started cutting. Here's the drivers side with the subframe mount cut out:
There's a metal cylinder in the middle of the subframe mounts that don't come with the new pieces ( its kind of a slotted deal for the bolt to sit in), so I had to cut that out of the old ones without harming it. In the following picture you can see it welded back into the two pieces that arrived from Wallontesch:
It was a bit confusing how the new pieces and the old thing fit together but after some trial and error I figured it out. If anyone has any questions about it let me know, I'd be glad to explain in further detail. Anyways, heres the other side of the subframe mount after it has been welded back together:
Do that process x2 and you've got new rear subframe mounts! I don't currently have any pictures of them welded back in place but I'll take some later today and add them to the post. Also, I don't have any good photos of the whole floorpan/floor setup with all the various extra repairs, so I'll have to take some photos of that to add to the floor pan repair party blog post entry.
Whew, that was exhausting just describing all the work up to that point, and we haven't even touched any exterior body work yet! More updates to come.
I’m trying to catch up a little now, I registered and insured it recently and have been driving it around as much as possible! I have had Recaro seats out of a mk2 jetta for a while and finally got some brackets to make the install possible. I was worried about the seats looking completely out of place in this car but it works good and man are they ever comfortable! Anyone interested in putting these seats in your car need the power seat versions as they have the six bolt recaro bases where as the manual VW recaros are vw specific. Also cleaned up the rear seat and finally put it in! This car sat inside and the interior really cleaned up nice.
Another thing that bugged me was the 2002’s original licence plate mounting position. When you mounted a plate it would cover the trim between the tail lights and leave a gap between the plate and the bumper. I didn’t want to drill holes and a licence plate bracket off a Mercedes actually works perfectly. I found that on the forum, so thank you! I took a picture of the part number for any other 2002 owners out there. It is super easy! I welded the bolts in place so I do not have to wiggle my hands in behind trying to tighten them to make it even easier. Also I did some research and in Alberta you can legally register your car under a vintage plate. So needless to say…..
Wiring! I cleaned up the engine wiring harness connector by ordering a BMW c101 Chasis side connector and the factory pins.
Just got some parts back form the powder coaters, including my 75 modified windshield washer fluid bottle holder. I moved this out of the stock location just to clean up the engine bay a little. I had to cut this bracket up to move the bottle out of the way of my throttle cable. The bottle itself is out of a 80’s Audi I think.
After driving it a bit I realised the stock radiator wasn’t cooling the engine as well as I had hoped. This three row, aluminium radiator seems to work well so far. This May long weekend was a warm one and it didn’t overheat. I’ll consider that a success!
So, a bitter sweet end to my 1975 BMW 2002 Mintgrun Lite Restoration has the car being shipped off to its new owner in Dix Hills, NY. I really enjoyed the journey and although it is not practical to own 2 2002's with a 3 car garage, I look forward to finding another car to work on. Just don't tell my wife!
I hope the new owner enjoys this car as much as did and starts a new blog on his journey.
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