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D.martijn

2002 Touring '74 from Belgium, full restoration project (Lots of pictures)

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Again a bit or progress on the 02 Touring,

 

I finished up welding the new flange in and grinded the welds flush a couple of weekends ago.

When we fitted the strut support piece back in we weren't fully satisfied with the fitment againts the newly welded in piece.

In hindsight we should have fitted it a couple of times more before welding in the new piece.

However, we still needed to cut out a little bit of rot where the strut support piece spotwelds onto the firewall anyway.

After cutting the rusted metal out, we adjusted the section where it needs to sit against the support piece and finall welded it in completly

 

Since it was dry and the sun was shining, we decided to sandblast this section of the car to remove the old paint and some light surface rust. turned out great!

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Next time we'll be able to weld in the support piece and then it's on to the next thing weld in!

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Today my brother and I took a day off at work to work a bit on the 2002.

Last time we finshed repairing the bulkhead/firewall of the Touring, before welding in the support piece.

I thought it might be a good idea to make a flange with a hole in the center to use as at plumb bob. This way we'll be able to measure the distance between the strut holes and to the rear subframe bolts.

 

Since I haven't had time to machine those flanges at work, we decided to start on "repairing" the font frame rails.

When shining a flashlight into the rails, they weren't rotten or very rusty. There was only some surface rust. But since we are here now, we might as well replace the top plates with fresh metal and threat the inside.

 

We had already replaced the rear section close to the drivers side floor, so we removed the original plate where we previously welded the new one onto. Some rust between the two sheets but overall not too bad.

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Threated the inside with Brunox after wire wheeling/grinding the inside

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Extra coat of Corroless anti rust primer, I did weld the remaining holes and grinded them flush. I went a bit too deep with my spot weld drill :)

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New plate

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Clamped into place

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And spotwelded, wow this thing is so awesome. Can't imagine having to plug weld these. I'm spoiled haha

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And the rear section welded + finished

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There is also a little metal clamp on the rail that holds the wiring loom going to the alternator and/or starter.

The old one was a bit rust so my brother made a new one

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We decided to also spotweld the old plate I welded in previously. Just so it all looks OEM :)

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On to the next side, same deal. Removing the old plate, making a new one and spot welding it in

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Finished result!

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Glad we removed the old plates 

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Edited by D.martijn
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Small update again.

Last weekend we also removed the brake line bracket at the drivers side and replaced a section of metal as it was rusted through.

I still need to sandblast the bracket before reattaching it to the inner fender.

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I has also ordered some more parts, we still needed cooling hoses etc.

Ordered all of those, genuine BMW + the according hose clamps as well. I decided to also order the middle console from BMW. I was a bit hesitant since on pictures online there were a lot of wrinkles in the vinyl covering. Well, turns out it's no that bad! 😊

Also made a second order at W&N for some sheet metal for the rear subframe mounting points.

 

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Excellent progresses, congratulations!
My Tii is now at the body shop for painting :-) Should come back in January with the body completly done! After 4 years of rust "eating", I'll be ready for the big "mecano" of reinstalling all the equipments.
Nice job you've done on the front chassis parts. Mine were in such a bad condition that I replace them by new part$$$$$!
Merry Xmas!
JP

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On 12/23/2019 at 12:11 PM, Toga said:

Excellent progresses, congratulations!
My Tii is now at the body shop for painting 🙂 Should come back in January with the body completly done! After 4 years of rust "eating", I'll be ready for the big "mecano" of reinstalling all the equipments.
Nice job you've done on the front chassis parts. Mine were in such a bad condition that I replace them by new part$$$$$!
Merry Xmas!
JP

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Thank you, yours looks great in one colour! Sonds like you have fun times ahead of you.

Is everything else ready to go into the car?

Happy holidays to you too!

 

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Last update for 2019!

 

I decided to start reparing the original rain/firewall scuttle. I still need to make a pressing form to press in the indentation for the rubber hoses But started on filling in the holes where I drilled out the spotwelds. Also removed the little wiring loom brackets to remove any rust between them and the panel + the back of the clamps as well.

 

Filled spotweld holes and finished top section where it's spotwelded to the middle support piece

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I'm also looking to buy a set of new copper electrode for the spotwelder so we can reach the fange where it's spotwelded to the inner fender

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And the removed clamps, Already repaired a few of them. When removing the spotwelds, some got drilled a bit too deep

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And finally we also repaired the heatshield for the exhaust manifold. The previous owner had but two sections out from the shield..

Small patch panel made and some new hole and voila. I'm considering to also get this plated with some other parts and nuts & bolts

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Some more work done on the rain tray for the firewall.

I filled up the holes I made to remove the spotwelds on both sides of the panel as on it's still in good shap on the sides.

The middle however needs to be replaced as it's rusted through.

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When we removed the panel a few years ago, we damaged the flanges on one side. so I welded on some new flanges.

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I also noticed the wiring loom clamp at the bracket for the windshield jets had cracked, so I removed the original clamp and made a new one. Still need to spotweld it onto the car

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As there was some interest in how I made the little wiring clamp on the "what did you do today" thread, I decided to also post it over here.

 

I decided to replace the existing ones on the firewall as well. Now that the rain tray isn't installed yet, I should be able to reach them with the long electrodes on the spotwelder.

 

Here's the quick "How to"

 

The original tabs are 15mm by 45mm. I used 0.8mm sheet metal but the original metal that was used is a little thinner.

I used the 0.8mm cuz I had it and I think it's less prone to shearing when bending the tab a couple of times.

 

After cutting out the tab, I fold over the edges until I have something like this. One end of the tabs will get hammered flat again so if only one side turns out ok it's good.

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I then band the two sides up, the side where it gets spotwelded onto the car is a little bigger.

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I then bend it over on some bar I had laying around. You to need to push it quite a bit for them to move it overall the folded edge maintains pretty good.

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Bigger side hammer flat again

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And corners chamfered 

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Repeat several time and you end up with these :)

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Small update, have been mainly designing/making a couple of parts.

First of were some new doorcard panels. These are still test pieces, a couple of holes need to be readjusted before making a couple.

I might try and sell some as well if there is interest.

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As well as the hatch/boot trim panel for the Touring

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Next up were some simple steel plates.

Before welding in the left strut support piece we wanted to measure the distance between the two and also front to rear.

Last week, I made a couple of plates that fit inside of the hole for the strut. I made these with our wire edm machine at work.

The hole in the center is for using some wire and a plumb bob.

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While the machine was running, I decided to try and make some new hinges for our Gold sunroof, starting with measuring the original hinges and drawing them up in CAD. I'll mill the steps and wire EDM the countour, for the plastic guide pieces I might make a small mold to pour resin.

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And this weekend, I decided test making some steering box shims. These are made out of some stainless steel shims stock.

Again, using the wire EDM to cut these out.

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Another update on the Touring (finally)

 

Couple of weekends ago, we spotwelded the left brake line bracket back into it's place. I also went a head and added some spotweld to the other one on the right side of the car. Just so it will all look equal once painted.

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Since wire EDMing the plates, we were now able to measure the distance between the two struts. We also decided to measure from the struts to the rear axle points and everything matches from left to right.

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The only measurement that seems to be off a bit it the width between the struts. They should be 99.6cm but ours measure 99.0cm?

Not sure why this is measurement is off, we test fitted the nose panel and the panel lines up nicely with the inner fender.

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Before welding in the we also measured the distance between the rear axle and the front subframe and the diagonal lenghts are all the same. So we went ahead and welded in the left strut reinforcement panel

I first plugwelded it from the holes we drilled to remove the old spot welds. After we grinded the plugwelds flush, we used the spot welded to add some more spot welds + this will make it all nice and OEM. We also added some on the right reinforcement panel since we had already weld this in before purchasing the spotwelder. Very happy with the results

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We also got ourselves a 3D printer, as some plastic parts are NLA. We might print a couple.

I've had a first try at printing the front seat rails caps, turned out pretty good. (I got the .stl files from @PaulTWinterton)

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Todat we flipped the Touring on it's side, to clean up the welds on underside of the floor and add a couple stitch welds where needed.

My brother cleaned some of the remaining welds in the rear wheel wells

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I had already cleaned up a couple of them but not all on the passenger side floor.

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And the drivers side, while it was on it's side, I also made a little patch for the small hole I kept blowing through when welding in the new floor pan.

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Pretty happy on how these came out on the underside

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And cleaned up. I decided to also remove the paint from the W&N panel since it's not the best 

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Couple of stitch welds on the front of the chassis rails

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And finished result! 

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Nice progresses! Congratulations. I hope you're doing well and don't have any issues with the virus! On my side, I'm slowly rebuilding my rear axle and fit the new brake lines. I also "attacked" the heating box which is quite rusted. I found the plastic parts broken or split at some places. Have you any idea which glue would be successfull on those plastics? I'd tried cyanide but it doesn't work.
Good luck with the confinement!

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13 hours ago, Toga said:

Nice progresses! Congratulations. I hope you're doing well and don't have any issues with the virus! On my side, I'm slowly rebuilding my rear axle and fit the new brake lines. I also "attacked" the heating box which is quite rusted. I found the plastic parts broken or split at some places. Have you any idea which glue would be successfull on those plastics? I'd tried cyanide but it doesn't work.
Good luck with the confinement!

 

Hey man,

Thanks you for you comment! Still got a long road a head before I even think about starting the build up again.

I would think some 2part epoxy would be a better choice for this? 

 

Thanks, you too!

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Small update on the Touring, some more rust repairs! (what else!?)

Overall the floor pan is in pretty good shape. However a couple flanges for the floor plug have some heavy pitting and some parts are rusted away.

Nothing too serious though.

 

Cut out the rust, make a patch panel and weld it in!

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Adding the little cut out for the plug and voila!

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We bought some correct floor plugs with the square indentation from a member on the forum, @jmbeatt2

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Couple other spots that needed repairing. Top middle and bottom left part were replaced.

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And a hole was added in the W&N panel I previously welded in

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While my brother made these patch panels, I finished the inside of the firewall by smoothing out some left over welds.

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I also made a die to punch the indentation for the rain tray, this is just a rest piece as I still need to tweak it a little.

But overall it looks promising!

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