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About this blog

Document my tenure with this car.

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Entries in this blog

 

Unboxing ross forged pistons

Gathering components for engine rebuild. The pistons arrived this week - here are the pics from unboxing including tech data.     

Dionk

Dionk

 

Smooth...Glossy & Stunningly beautiful

Major milestones achieved.  1. While I’ve only seen it in side a building the paint is fantastic! Derby is grey once more. 2. Head built.     Next big big milestone is the bottom half of the engine!    Stay tuned. More pics to follow once it’s back home. 

Dionk

Dionk

 

W&N goodies! 292 schrick, hardware and hood bits

Another package of goodies arrived today for W&N - pics of said goodies attached.   Decided to have a professional rebuild my head instead of doing it myself because I tend to break things, over tighten and take twice as long as it should.  So Friday afternoon I dropped off the metric mechanic head, Korman intake and associated bits to a local engine builder RAC engines in laurel MD. I’ll be dropping off the new cam for him later this week.    So - Slowly coming together.   paint update - there is none.  its been a few weeks since I dropped the car off for paint and quite honestly- I’m nervous.    My my worst fear of is that they close down and I lose my car and deposit -  like I said Worst fear. Second to worst is that they take forever to finish.   I don’t want to be a pest by calling every week - but I’m going to anyway.   Over the the weekend, I got a few seals replaced on the getrag 245 (input shaft, and selector shaft seal).   Had and some troubles getting the selector shaft seal in because of a prior guibo/flex disk failure damaged the transmission case. Pics of that in the general discussion area.   I still need to change the output shaft seal- but I don’t have the right tool to get the bolt off - think it’s the thin walled deep impact 30mm.    That’s it for now - wish me luck

Dionk

Dionk

 

The waiting is the hardest part.... miss you Tom petty

Yeah...so no cool pictures to share at the moment.  Will add some later today of some new parts I’ve acquired.    So so while the car is off being painted, im getting some things ready and this weekends project will be to review my overall plan and start preparing my e24 rear seats.     Here is a preview / overview of the build   I have been accumulating parts in anticipation of getting it back from paint.    For the engine  Today I’m meeting a guy in Tyson’s to buy a metric mechanic e12 head.  I have brand new  dual Weber 40s, Korman intake, stahl header, a dr schrick 304 degree cam (evil grin),  new alternator, e30 m3 starter, all new seals,  etc... and the debate (regulated by my own fiscal constraints) is whether I should attempt to assemble this myself or pay a shop to do it. Which goes for everything below as well.  If there is anyone local to Arlington VA, that knows how to rebuild a head...I could use some help.   Transmission  E21 5 speed and Bluntech’s new ultimate 5 speed install kit. New seals for transmission.    Differential E21 3.91 ( new seals), inner cv joints from e21 will be mated to the 2002 half shafts.    Drive shaft Not sure what to do - buy a shortened one or have the drive shaft from the 71 shortened or modify the e21 drive shaft I keep from my e21 part out.    Brakes Single circuit setup.  E21 250mm drums in the rear, 1977 e21 big calipers and new rotors in the front. Rebuilt 2002 brake booster, new brake lines, and e21 master cylinder.    Interior    E21 Recaro seats for the front, e24 seats in the rear all recovered in cardinal red textured vinyl.  New carpet, new headliner, stereo system, new momo prototipo steering wheel.    Exterior Euro turn signals, new roundie lenses and seals for my tail lights, new seals for all the glass.   Suspension This will be a swap from my orange 71 2002 as I replaced everything bushings, control arms, etc..in 2017. Notably it will include bilsteins, and possibly the h&r lowering springs. TBD on the springs because I’ve not finalized my wheel decision.    So that’s my update for now...I’ll post some pics of the head and the e24 seat work soon.  

Dionk

Dionk

 

Time to let the professionals take over

With mixed emotions and must say after 1 yr of trying to get the paint and body work done myself with my friends help, I’m throwing in the towel.     Im sending Derby to some professionals to figure out the paint and bodywork.   I’m still roughly sticking with the original color of Derby Grey (Griogio medio).   here are some pics of derby leaving home 😢😉 1BE59B9A-DC65-40C1-8248-694E83E45026.MOV

Dionk

Dionk

 

Well - two steps forward - 2 back

Thought I’d post an update.    Luckily my buddy that’s helping me is willing to redo rework when we are not happy with something. So the painting continues.   Paintedbthe calipers red with VHT and VHT high heat primer. Not a fan. Sanding them back down and going with the VHT “Real Orange”   Interior and bottom of the car has been  sanded, cleaned and painted with POR15.    It never goes as fast as you think it will but, I have not lost faith.    Adding a little more Italian.  In that I’m still accumulating goodies as well latest addition- pictured below. Brand new MOMO prototipo!   Hand made in Italy. Seriously beautiful! And a nice compliment to the Ferrari Grigio Medio paint.    Happy new year 2002 friends.          

Dionk

Dionk

 

Accumulating Parts -

Dual Weber’s 40’s cannon manafolds ( have Korman as well no sure which to use) Bosch e30 m3 starter Bosch alternator  Blunttech 5 speed convenience kit front wheel bearings etc...  

Dionk

Dionk

 

Cleaning up my calipers

Lots of life and work things going on, though I managed to get a few minutes in the garage with a wire wheel.   

Dionk

Dionk

 

Goodbye to my e21

Well - there she goes.   Our time together was short,  but I did get to daily her for a few months.    She gave and she gave - I took and I took.   Now time to put her best parts into Derby.     On with the show!     

Dionk

Dionk

 

Back to school: “what did you do this summer“

Greetings all! Not sure who’s actually reading these posts, but I do enjoy posting about my progress.   So summers been a little bit slow as far as working on the 1602 goes.     But progress has restarted and the quest to achieve a semi-decent paint job is on going.   You’ve probably heard of the saying two steps forward one step back. Well in my case the summer it’s been .25 steps forward and four steps back.   But I’m happy because progress is indeed being made once again on the paint.      I spent the better part of the month August parting out my 1981 BMW 320Is. I felt a little bit bad parting out that beautiful E 21.   really   I truly felt a bit guilty, but seeing that limited slip differential and that five speed transmission and all the other cool little miscellaneous parts stacking up is pure joy.   But don’t worry this story has a good ending.   The E21 frame/shell is going to a good home, a local shop owner is taking it on as a project car.   This weekend we will be removing the engine and the buyer will then take the frame any all the remains goodies at that point.    My buddy who’s been helping me paint and who has also been missing in action this summer (who can blame him it was hot here in DC) is back up and working on the car on a daily basis.   I also spent this past summer acquiring parts for the engine build.   Here are a few pics.

Dionk

Dionk

 

Pause for the cause -

No remorse - removed the LSD off the parts car today.   Had a visit from a fellow faq member and closed a deal at work.   Overall a good day.   Getrag 245 - you're next.

Dionk

Dionk

 

A few pics of the heater box mid overhaul.

Overhauling my heaterbox.  Repairing cracked plastic....wow it’s fragile.  Don’t ask me how I know.  Also if you doing this and reusing your fan blades on a new motor. A Quick way to determine which way the fan blows is to attach it to your drill before punching out the center shaft to affix to new motor. Also not that I read a post somewherethat if you reverse the wiring the fan may blow in a different direction...so there’s that way as well to be cautious of.     Did i I mention this 50 year old plastic is fragile..  F&#& !!

Dionk

Dionk

 

Heater core removed! Now to overhaul.

So with the dash out it made sense to also pull and contemplate a heater box overhaul as well.   So I pulled it from the car today. Fairly easy qty 2 11mm on the bulkhead and two clamps to detach the hoses.    Set it down and cleared away the discintegrated 50 year old foam.    As others have warned...there is still antifreeze in the unit!    I layed down some linoleum on the passenger side floor and tilted it out to that side.... sure enough.    If your doing this job as well have rags/ paper towels handy.   Variety of pics below.

Dionk

Dionk

 

3 piece dash removal - notes & pics

I read as many threads as possible on three piece dashboard removal and attacked the job today.     I found the threads with pics to be most helpful. I think it was pho23 that had a some great pics and I gave his DIY thread titled "Removing a 3 piece dash." dated  oct 28 2007 thread 5 Stars.   i followed the steps he described in the thread and found no issues with the instructions at all.       Here are the things I broke in the process.   1. Air vent hose to plastic dash vents.  2. Tabs on the plastic dash vents.   3. A couple clips pulled off the dash and stayed in the car.    My advice is to go slow to a avoid the mistakes I made.   here are the pics    

Dionk

Dionk

 

Random new parts

Various zinc plated hardware!  Rebuilt brake booster steerbox refresh kit fire wall sound proofing    

Dionk

Dionk

 

1600-2 Rear subframe and pics of the undercarriage

So I have removed the rear subframe and all that remains with the body of the car is the wiring, the dashboard and the heater blower motor thing.    The goal will be to sand and degrease the undercarriage before coating the bottom with some POR15.    I only found some minor surface rust.  Especially where the brake line tabs connect to the body.    there was some rust in the forward floor panels that had been repaired before. Welding job clearly Needs some additional love.   here are the latest pics. 

Dionk

Dionk

 

Better to take the doors off!

So I must say...I'm so pleased with this car! It’s 50 years old and 98.3% rust free!  I keep giggling! Today's giggles started when we got the doors off and I closely examined the bottoms!  Nada rust. Lovin it.

Dionk

Dionk

 

Today's progress

Engine bay, wheel wells and prep.....lots of prep. Sigh.  At some point a previous owner coated the wheel wells with tar or grease - holy cow what a huge paint to clean.

Dionk

Dionk

 

Getting closer

Well if you curious the DIY paint in the garage paint job is getting close to being done.     Here are are a couple pics - cloudy day can’t wait to see this car in the sunlight - running.  Yeah that would be nice as well.

Dionk

Dionk

 

Engine and subframe lowered

Today we dropped the engine, trans and front subframe.     Progress.   also found out that I have a stall header!  Bonus

Dionk

Dionk