I have been working on the 2002 a few hours each week, ordering parts as I remember I need them and installing them as they come. The biggest thing is that all the replacement floors are now installed with only some more welding needing to be done for structure. The interior looks so much better now with the new floors, It actually looks presentable instead of looking awful like it used to with all the rust holes and riveted patches.
Once the final welding is done I will start to clean up all the small surface rust spots elsewhere in preparation for carpet, but there are other priorities first.
I also cut out all of the rust on the front nose but have yet to decide whether I should patch it up or put a spoiler down there and leave that as some maybe not so professional airflow to the radiator and intercooler which will hopefully be sitting inside there.
The only other rust spot that is rusting though is on the passenger side in front of the rear wheel bubbling the paint which still needs to be addressed. With fixing that rust and with the rest done it makes me wonder if I should repaint the car its original color while it is mostly apart. The paint that is on it now is purple in sunlight but is in fairly good shape with only some scratches and chips but a good clear. stripping off the paint on the car to repaint it also worries me; this car will never be concours, I fixed the riveted patches on the floors but there are also riveted patches on the inner rear wheel wells and the rear quarters look good from the outside and have held up for over 10 years but looking from the inside, the metal there is held on with bolts and It looks like a ridiculous amount of rust was repaired there being a east coast car. If I start stripping the paint I am afraid I will will find tons and tons of puddy that will need to be completely redone to look decent.
In happier news I have made progress with modifications. I used the front half of a 320 driveshaft matted with the rear of the 2002 driveshaft and had it shortened by the recommended driveshaft shop here in Colorado. The driveshaft is now in the car with the lsd I had. I still need to sort out the attachment of the cv axles to the differential, I know ireland engineering sells the necessary parts but I don't know if I want to pay for all those parts if the money could go toward something else as I am on a budget. I measured the difference in widths of the driveshaft myself and as of now, have fabricated one spacer for the diff in the home machine shop, I can put up a picture of it tomorrow if I get around to it.
On the engine side of the drivetrain I have made much bigger progress. I put the battery in the trunk and actually used the battery cable from I believe a e39 which is just the right length to go the the firewall. With the batter positive all hooked up, I finished the last of the engine wiring with the installation of the last fuses and the attaching of all the positive wires to the positive terminal. I still need to source and attach a alternator ( I somehow lost the one I had ) and attach the starter but in the coming days I will be doing the first tests of the electrical system, making sure the megasquirt turns on and that nothing catches on fire.
Aside from the electrical system I have been installing all of the oil and coolant lines and pondering where and how to route the intercooler and turbo piping. I ordered all stainless steel braided lines for the oil and coolant and now I smile at the beauty that the engine is becoming with all the shiny new parts.
To hide all of the wires along the engine, I turned all of the old CIS injections in hooks that channel the wires along the engine.
Also as part of my saving money I made the idle control valve instead of buying it because if I have the tooling and the time, why not.
I also installed a 320i radiator and set it back a little to fit an electric fan and maybe the intercooler in front of it.
Some old pictures I forgot to include. The 2002 crankshaft pulley had a chip in the air pump pulley, so I just put it on the lathe and turned it off to make it balanced
I also forgot to include that I attached a trigger wheel to the pulley and made a holder for a hal sensor
( all of this was before the engine was in the car )
A lot of progress has been made but I don't know whether the end is close of far away. The engine in close to being done, but there is still so much left to do and more things that could be done to make the car look nicer.
Likely the next big thing that will be done is getting the exhaust made, filling her up with fluids and trying to see if I have any tuning skills whatsoever to get it to idle.
It will likely not look pristine for some time, the priority is getting the car running and in a position where it can be driven. It is the beginning of the end to the modifications on the car, I very much look forward to being able to drive a 2002 for a first time. I have also not put anywhere that I am 19 now so I think Im doing pretty good, but I'm prepared for the worst as the engine is getting close to being started.
Since the past entry I have slowly been replacing parts as needed. I all four new floors from wallonthnesch shipped to me in three days for 260 which I found amazing.
As of now all but one of the new floor panels has been replaced.
They all fit very tightly and look exactly like the original; At least I think they do considering I couldn't even see the pattern of the drainage passages in the back. I also took out the petal box to fix the rust hole that it had and replace the bushings. The passenger floor was entirely replaced some time around 1990 and was just a bolted and welded on piece of galvanized metal that was a pain to get off. There was a continuous weld on the bottom to the subframe and some weird layer upon layer to raise the floor or something.
The only other major rust problem now is the rust that is on the nose of the car; but considering that the car can still be driven with that rust and there is no rust anywhere else, the repairing will have to wait till the car is painted.
The engine also finally went in and it looks much better than the oil splattered engine that was there before.
The turbo is on the car and unlike most turbo builds that I have seen, the turbo on this motor is below the exhaust manifold which ended up being a tight squeeze trying avoid hitting the heat shield and subframe.
The overdrive 5-speed I sourced went in with the engine and now all the "extra" bits are being put together including turbo piping, oil lines, megasquirt wiring, coolant lines, shortening the driveshaft and installing the lsd differential.
Looking into the wiring of the car has been interesting. One or both of the previous of the 2 previous owners of the car did some modifications to the electrical system that is very complicated and not the best quality work, but obviously took a long time to put together. There is only some wires added to the engine bay that go to the square hella fog lights, and some other wires that splice into random places on the wiring harness and do something, I have no idea what. Inside the car I have found tons of buttons, plugs and switches with wiring under the dashboard covered with rubber tubing that makes me think that the first owner of this car may have been James Bond. I will not be getting rid of any of the switches, but will be finding new purposes for them as they do not look super ridiculous and are kind of interesting.
Here is all the switches on the top of the center consoles with the lights,
and here is the wiring under the center console and yes, that is windshield washer tubing covering electrical connections
Then there is this plug under the steering wheel which I do not believe is original considering it has crimped on connections on the back
Then there is the other random wires under the steering wheel which attach to random connections that have been made.
These particular wires go to the frontfoglamp button which looks like the letters have been changed? Notice the "A" and "M" are slightly filled in
Also if you look you will notice the little red light with a identical one on the other side of the gauge cluster that attaches to the switches, I believe..
I also found a switch while following the wiring that was hidden in the glove box.
Oh, and there is one wire that goes to the back of the car and down out by the exhaust for some reason; Possibly a tow hitch?
And then the final wires seem to be for speakers or something but are super long and go from the dashboard to under the back seat and attach to nothing, that is how the wires where found
Unfortunately it does not seem as if there is any missile launchers or ejectors seats in the car but hopefully I can sort through the wiring and start getting the engine management hooked up to see if I can finally start the engine having acquired it come years ago, rebuilding it for some time, and then searching for the right 2002 to put it in. The progress will continue with most all of the work hopefully done before summer is over.
After looking for a 2002 that fit what I was looking for for some months, I finally found one back some time in august. I bought a 1975 2002 that you could consider a barn find. The 2002 was sitting under a canopy and had not been driven to my knowledge since about 1994. According to the person I bought it from I am the third owner of the car. The car was very low because of completely flat tires so the bottle caps where put on replacing the original rims so it could be rolled.
I then proceeded to rip out the interior of the car because I have e21 recaros that I plan on installing along with a new carpet. Upon removing the carpet I found the rust that I could not see before. The car has had previous not so great rust repair and I will be replacing all of the floor panels.
The good thing is that I bought it for cheap and it has a bad engine which is what I was looking for as I have a rebuilt replacement. The color is is right now turns purple in light and is not very nice to me, but the original color Is a rare arctic blue metallic that as I have read is rare and was only offered on the last years of the 2002.
Driver floor with cut out gas pedal from rust:
One of many old rust fixes:
Original color sticker:
Today I have removed the engine and hopefully will get my rebuilt turbo engine in some time.
That is the end for now. My goals for now are to just get it driving; which means fixing all the rust so I actually have a gas pedal to press and to put in my engine.
A funny note to end on.
my 2002 won a bmwcca clean car award when it was 2 years old. I find this kind of funny.