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D.martijn

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

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Today I continued on the repair of the rear shock tower of the 02 because I didn't want to get the neighbors angry on a nice sunny Sunday and I didn't have time on Monday..
I first thought I might be able to reuse the original piece that I cut out and replace some of the rotten bits, I decided this would be too much of a hassle so I tried to form the repair section from a flat piece of 0,85mm sheet metal.

For the little step down section I was able to use some flat jaw welding vice grips to form it. To make the curve I bended the piece by hand and some hits with the hammer & dolly.
Still too big but getting there..
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After trimming the exes off, some more forming and drilling the holes for plug welding
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Had to ground some more off, ready to weld. These are some handy little clamps
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Fully welded and cleaned off.
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Detail of the step down, pretty close to the original shape. (Looks like it doesn't show up that good on photo)
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Checking the underside for penetration, seems to be good
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Jig fully removed and zinc primer added
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Only thing that"s left is grinding all the welds down, welding a bead on the middle support and 4 beads on the side of the inner piece.

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Yesterday I received a new book in the mail. Very nice quality and at a first glance some great information about the 02s.
IMG_20160817_180228_zps4wklepic.jpg

Today I had a look at the Hofmeister Kinks of our Touring, it was pretty clear that these will have to be replaced/patched up.
IMG_20160818_122624_zpspz47hvoj.jpg

First layer of metal removed, exposed some more rust
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Second layer removed, looks like there is something missing :PIMG_20160818_144154_zpsybu4tfg0.jpg

Last piece removed, I still have to remove the flat piece too.
This will now get sandblasted before I put new metal in.
IMG_20160818_153857_zpssly1agnm.jpg

As for now, I sprayed some zinc primer on it to protect it a little bit till it gets sandblasted.
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We were able to save this piece from the cut up shell, this is in much better shape than our kink
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Here is a shot of all the layers, I thought some people might find this interesting :)IMG_20160818_164459_zpsxjvub2rz.jpg

Other side, not as bad from the inside
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Forget what I said earlier..
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Everything removed except the flat piece. Same deal for this side, the replacement piece we got is in much better shape.
IMG_20160818_190501_zpss0su87jj.jpg

 

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Today I went through all the parts that we want sandblasted by the guy that will sandblast our shell.
Still need to disassemble a few things further and remove some of the rubber bushes of the suspension bits.
There was a discount on the suspension bushes from WallothNesch I of course placed an order, great timing!

After sorting that stuff out, I had a look at the lower right side corner of the front a pillar. It was starting to get pretty thin on the seam where the window rubber sits over.
I first cut the required patch out of the panel that came from the cut up shell we got.
Then I marked the outline of that piece onto the corner and cut most of the rotted bit out.

Here you can see the rusted lip still in place.
IMG_20160820_172458_zpsxahpwt4k.jpg

Then drilled out the spot welds and test fitted the patch. Still a bit of grinding left to make it fit.
Now that this piece is out it'll make it much easier to sandblast the inside
IMG_20160820_172858_zps8iqwdktk.jpg

IMG_20160820_172508_zpswvudnqzy.jpg


 

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Our order form Walloth Nesch arrived this week, mostly rubber suspension bushes, some hardware and the rubber protection tube since it all was on discount
IMG_20160823_123330_zps9u86sx9o.jpg

We also got 3liters of epoxy primer so we can paint our shell when the sandblaster comes on Thursday
He will also sandblast the suspension parts so I gave the local powder coating place a call, all set :thumbs:IMG_20160823_123338_zpsgzkjchym.jpg



 

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Yet an other update!

Yesterday evening we set our big party tent up in the backyard. This will serve as a blasting booth.
Hopefully it'll keep most of the dust inside :)

Today I still had to disassemble the steering column, luckily I found the right instructions in the BMW Shop Manual.
The shaft will get galvanised and the column blasted and painted black.
IMG_20160824_132958_zpsp3mwbblw.jpg

I also removed the rest of the old A pillars and the flat piece of sheet metal on the C pillar.
IMG_20160824_223518_zpszfiisda9.jpg

Also get everything that needs to get blasted ready and masked the surfaces that don't need to be blasted.
Struts, shafts, suspension bits..
IMG_20160824_223337_zpszbxdukfj.jpg

Exhaust manifold, pedal box, brakes and some sheet metal parts..
IMG_20160824_223412_zps5t3z6py3.jpg

Real trailing arms
IMG_20160824_223431_zpshxbnmrj0.jpg

Front & rear subframe, rear springs, brake parts & sway bar..
IMG_20160824_223447_zpsbkjuwzes.jpg

Front nose panel

IMG_20160824_223456_zpspcfrpgrh.jpg

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This is one of many cool parties to attend.  Thank you for the long distance invitation. 

 

What should we bring?  What is the dress code?  :)

 

 

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@2002haus Hahaha, Thanks for the great comment, it put a smile on my face! :)

 

It was actually a pretty hot party at 95°F outside temp, even hotter inside! 

Dust mask is advised, a broom optional.

 

___

 

And here it is, the long awaited sandblast update!

Most nooks and crannies got sandblasted. We didn't sandblast the big flat panels to avoid warpage.
When blasted I went over the whole car with compressed air to remove all of the sand and rubbed the car down with white spirit to remove the last bit of dust.
Then I sprayed Brunox on the places where there was some pitted rust. Finally everything for a coat of epoxy primer.
First time ever using a spray gun, painting the car went pretty good. I first started with the bottom of the floor to get the hang of it.

I'll just post pictures now ;)

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Today I welded the new replacement A pillar corner on our car.

I started with cleaning up the epoxy primer on the edge where I'm going to weld. I also coated the inside again with some Brunox then some zinc primer.
IMG_20160829_145512_zpsebtl7ywo.jpg

Making sure the piece fits, these handy little magnets make it much easier.
IMG_20160829_145603_zpsnba7zn47.jpg

Tacking the piece in place, had to do some fiddeling on the right side as the weld shrunk the metal pretty hard on that side.
IMG_20160829_151819_zpsvrxxwj4o.jpg

Hard to get this on picture but both edges are nice and flush
IMG_20160829_152615_zpsun6hafey.jpg

Ground all the tacks flat. 
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Ground the spot welds too
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Wasn't happy with the little flange so I filled it up and ground it smooth again, looks much better now.
IMG_20160829_164835_zpsznrefuzn.jpg


I pulled the flange from the firewall where it meets the tunnel when we sandblasted the car since there was some slight rust forming in there. I now hammered it flat again and gave it a coat of zinc primer.
IMG_20160829_150217_zpsbpmxtnmw.jpg


I also got started on the other A pillar. I have to fabricate some new metal on the backside of the corner since it's rotted there too. Pretty hard shape to make so I'll have to make it from 2 pieces. 
 

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(edited)

Another day, another A pillar!

Today I got started with the left A pillar.
I first had to patch the backside of the pillar since it was rotted pretty bad. I gave the whole inner section a liberal amount of Brunox too.
Pretty hard to bend such a patch from a single sheet of 1.2 thick metal so I decided to make it from 2 smaller pieces.
IMG_20160830_130223_zpsfaq7jtfq.jpg

 

Fully welded
IMG_20160830_135820_zpsbszoy61s.jpg

 

Ground smooth, still have to clean it up some more.
I think this will be pretty easy when I receive my pneumatic angle die grinder and power file.
IMG_20160830_141046_zpswgsd5ebr.jpg

 

Cleaned up the epoxy on the side and coated the inside with zinc spray
IMG_20160830_154949_zpszoypsckp.jpg

 

Here you can see the upper patch panel. I also welded it from the inside (like it came from the factory)
IMG_20160830_154954_zpsfbdtukxq.jpg

 

Replacement panel welded in. I had to make a small patch panel too because my replacement panel was just too short.
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Welds ground flat. It looks pretty good, although I had a hard time fitting the panel on this side.
IMG_20160830_182236_zpsr59f7g5u.jpg

 

Also coated the backside with some zinc primer.
IMG_20160830_182244_zpsdvqd60oi.jpg
 

Edited by D.martijn

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This time I got started with the left C pillar.
A few posts ago I showed some pictures of the rotted bits I removed. Time for some fresh metal!

 

I started with carefully taking the replacement pillar apart.
I was able to save the reinforcement pieces
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I sandblasted both pieces and gave them a coat of zinc primer
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To repair the C pillar, I have to repair the panel where the trim rivets onto. This was a simple 90deg bend.
Great having a crude sheet metal brake on each corner of our car thanks to the tilting jig  :thumbs: 
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Next was making another 90deg piece, this one needed a stepdown on one side.
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Bended stepdown piece in place, both pieces will be plug welded together
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After making sure the 2 smaller pieces would fit, I tried fitting the reinforcement piece of the pillar.
Luckily it was easy to line it up thanks to the hole for the rear seat belts and another hole.
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When I was sure it would fit, I welded the little pieces in place and grounded the welds carefully smooth, making sure that I didn't touch the edge.
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I then cleaned up the epoxy primer off of the sheet metal for the reinforcement piece. As I was grinding, a screwdriver fell from the roof right on to my can of zinc primer. What a coincidence that the point hit the rim of the can. The can lost all it's pressure.. 
As it was an almost full can, I took an old jar and poured the zinc primer into it. I'll apply the primer from now on with a brush..
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Gave both the top and underside a coat of zinc primer. The brush actually made applying the primer on the underside very easy.
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It took some time but also the reinforcement piece fitted nicely. it too got a coat of zinc primer.
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Welded in, had a hard time welding the plug welds, not sure why.
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Everything got grounded flat.
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And finally a good coat of zinc primer.
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Tomorrow I'll finish the pillar by welding in the smaller reinforcement piece and then the top plate.
 

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Today I finished the C pillar, well almost.
Only thing that I have to do is welding a new lip to the flange of the quarter panel. But before that I'll have to sand the welds flush with the powerfile I ordered that still hasn't arrived yet.. :dry: 

I started with welding the smaller reinforcement piece. I also plug welded it on one spot to make sure I wouldn't shift.
Normally it's only spot welded against the metal sheet I'll install next.
IMG_20160902_145540_zpsyfarkqjo.jpg

 

By making a template of the c pillar before taking it all apart, I was able to easily form the metal sheet that goes over the small reinforcement piece I just welded in.

This time my plug welds were pretty good, got some good penetration on the other side too.
This piece is plug welded to the piece I just welded in.
IMG_20160902_153357_zpsrff4alln.jpg

 

IMG_20160902_153440_zpslc5uezqw.jpg

 

I then welded some beads at the sides (like factory) and gave it a final coat of zinc spray.
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I also welded everything to the 90deg bended piece I installed yesterday. The welds still need to be ground flat. Also coated this in zinc primer
IMG_20160902_160205_zpsmvoseqzz.jpg

 

Quite the difference!

IMG_20160818_125629_zps6unkul1j.jpg

Edited by D.martijn

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Finally received the pneumatic tools I've ordered :)
Feels great in the hand and has some nice weight to it for only 30-40€. I also bought several sanding discs etc.

 

Angle die grinder and powerfile 
IMG_20160905_122250_zps7kgxvlu8.jpg

 

Tested out the powerfile by sanding down the welds on the C pillar I replaced and cleaned it up some further with the angle die grinder.

IMG_20160905_122205_zps3gld3e3s.jpg

 

I also started disassembling the replacement C pillar for the other side. This one had some more rust and might need a bit of patching.

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