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      Introducing FAQ Memberships   04/17/2017

      I 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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So....Where was I? (2016 Catch-up part 1)

xr4tic

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Now that winter is over and the weather is nice again, it's time to do some more work on the '02.

 

But first, I'm long overdue for a catch-up post, so here it is.

 

With all the cooling hoses off, I pulled the heater box out.  The fan didn't work and the heater valve cable was broke.

 

Pulled the box:

20160805_205218.thumb.jpg.d703a573fd4fbf0c7eeb7353cddf0775.jpg

 

The heater valve and broken cable:

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Inside of the old valve:

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Lots of WD-40 to break free up the lever/cable clamp:

20160819_144047.thumb.jpg.e24be6b7a79416b4e9e4c84201efa85b.jpg

 

I used the rebuild kit from Blunt for the Heater Valve, bought a new fan motor off Amazon, and a new Bowden cable from Rogers tii

 

I needed a solution to mount the old fan to the new motor, this is what I came up with:

20160910_225322.thumb.jpg.c0d748f92cb29432154eca27531b9b0a.jpg

20160910_225353.thumb.jpg.e0ee9539ddc2b6dc1e243a3d87b8bce4.jpg

 

I bought some aluminum collars off Amazon and brazed them to the fan.  Be very careful, too much heat will warp the fan.  I spent a lot of time getting it straight again.

Collars:  https://smile.amazon.com/gp/product/B0063KT4LW

 

Cleaned up the overspray on the cover and gave it a fresh coat of paint:

20160910_230130.thumb.jpg.7374cb2fe942ce3591ce11e7d200c08b.jpg

 

I took the heater core to a radiator shop, they cleaned it and checked it for leaks, didn't even charge me.

The heater box is all assembled and ready to go back in.

 

Unfortunately, I discovered the source of the water leak in my car:

20160805_205112.thumb.jpg.b1afabc631b300ba580bfce54f937cad.jpg

 

The bottom lip is almost completely rusted away.  I'm not sure if I should just cover it up with an epoxy paint and seal it real good, or have a new piece welded in.  I'll save that decision for later.

 

While the heater core was out, I figured I might as well clean up the wiper box, it had lots of overspray on it too:

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I got another intake manifold, but didn't like the carb spacer the PO had used, it looks like it was for a 32/36, so I bought a 1/4" thick phenolic sheet and made my own

 

Who says adults can't play with crayons?  Made a rubbing of the bottom of the carb

20160819_162451.thumb.jpg.c48a16a64e2b31563d0c63f71cd34a32.jpg

 

Used my dremel to cut out the spacer, here compared to what was on there:

20160821_153717.thumb.jpg.426f0fe2e596596c17daccf1d82619c6.jpg

 

Overlay comparison:

20160821_153737.thumb.jpg.554a711b2318bfbef27083df56365a1e.jpg

 

The intake holes had to be opened up:

20160821_153917.thumb.jpg.44c474848479633c65673ee557542265.jpg

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20160821_172807.thumb.jpg.de0fbd2f9d52c6e555c4f8d16e6df386.jpg

 

Fresh coat of cast aluminum engine paint and mounted:

20160822_204218.thumb.jpg.4a8cb710d57b7b1afb1ccd4d6390d0cb.jpg

 

Can't put the old carb on it without a rebuild, right?

 

So apart it comes, crud inside:

20160822_204259.thumb.jpg.ad5969b65635073a3527a14b9a746da1.jpg

 

Crud in the filter:

20160822_204249.thumb.jpg.53f554be1786b80c6ae7360650b4f5a2.jpg

 

Had to make my own gaskets:

20160824_225257.thumb.jpg.b8021a8385ff433ed0bbb8fafc6a672a.jpg

 

 

And that's where I'll leave it.  More to post for the catch up later.

 

Updated numbers:

Heater valve repair  $92.00

Blower Motor           $70.00

Collar                        $8.00

Bowden Cable         $45.00

intake manifold      $100.00

Phenolic                  $13.00

Carb Rebuild Kit    $100.00

Weber Jets              $50.00

Running Total     $9,067.00

 



3 Comments


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I didn't know the blend valve could be opened up. Mine is stuck. I may have to see if its full of gunk too. I dig the match porting of the carb to the intake plenum. Nice work.

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very nice work, love to see some customisation with the intake and home made gaskets! they charge too much for those things 

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10 hours ago, heinemann said:

I didn't know the blend valve could be opened up. Mine is stuck. I may have to see if its full of gunk too. I dig the match porting of the carb to the intake plenum. Nice work.

 

There are two types, mine is the later type with the plastic valve inside.  There is a good rebuild article here:

I cleaned up the housing and top by soaking it in a 50/50 mix of white vinegar/water mix, just be careful if you have put any of the steel components in the mix, the vinegar will eat them up.

 

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