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2002 rust bucket

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Took me awhile to start a thread, but to sum up the build so far I got the car about 5 years ago when I was 14 as a kind of father son project, although I've done almost all of it myself. It is a 1974 green 2002 that's far from perfect. When I got it it had mildew all throughout the interior and their was rot and rust everywhere. I stripped out the interior and ended up having to throw most of it away. The seats were pretty worn out but they are the nice recaros from the e21 so I bought new covers and reupholstered themmyself which was a pain but in the end it was worth it. The car was also a automatic and that's no fun so we found an e21 that had been sitting in a field for a while and pulled the getrag 245 out of it, originally we had bought a transmission off of ebay that had been titled "BMW getrag 5 speed" or something like that and when it showed up it ended up being a getrag 240 so we decided to go back on the hunt for a 245 which luckily we were able to find. We had bought a manual pedal box but it was all rusted out ($15 on ebay) I was able to salvage the pedals from it and then modify my pedal box to work with the manual. The transmission was a little hard to get lined up but with a lot of massaging of the tunnel we finally got it to fit and then got the drive shaft shortened to fit. The engine runs great for being a 40+ year old car and with just headers on it its a blast to drive, as well as deafeningly loud. the passenger side floor board was totally rotted out so all the exhaust fumes would just funnel into the cabin as well as all the sound. My uncle's friend has a bigger shop and more tools than my garage so back in January we took it there and dropped it off to fix all the rust and do all the body work and paint. We welded all the trim holes and the front and rear reflectors and all the holes from the big diving board bumpers (as they will not be going back on). I sanded the whole car and made all the transmissions smooth, the car has been t-boned on both sides and the drivers side fender is all crumpled, the passenger side t-bone was pretty bad and hit the trunk too so I stripped all the paint off and took it down to bare metal in those areas. I also sandblasted all the rusted areas which consisted of 90% of the car and me finding sand for the next month in all the wrong places. bmw 2002 rear.JPG

I sprayed some epoxy primer down to prevent the bare metal from rusting and then started laying down mud which is where I'm currently at. black 2002.JPG2002 with mud.JPG

The spare tire well was rusted out and rather then buying a replacement one I just bought a sheet of 20 gauge cold roll and made my own, when we welded it together though we did it backwards and didn't realize it until we went to test fit it so I spent the second half of my day today cutting out all the welds and flipping it over.

spare tire well.JPG

as you can see we had the base flipped over when we welded on the sides

2002 trunk.JPG

The second try worked pretty goodimageproxy.php?img=&key=c723ef59fd17d18fimageproxy.php?img=&key=c723ef59fd17d18fimageproxy.php?img=&key=c723ef59fd17d18fimageproxy.php?img=&key=c723ef59fd17d18fimageproxy.php?img=&key=c723ef59fd17d18fimageproxy.php?img=&key=c723ef59fd17d18fimageproxy.php?img=&key=c723ef59fd17d18fimageproxy.php?img=&key=c723ef59fd17d18fimageproxy.php?img=&key=c723ef59fd17d18fimageproxy.php?img=&key=c723ef59fd17d18fimageproxy.php?img=&key=c723ef59fd17d18fimageproxy.php?img=&key=c723ef59fd17d18fimageproxy.php?img=&key=c723ef59fd17d18fimageproxy.php?img=&key=c723ef59fd17d18fimageproxy.php?img=&key=c723ef59fd17d18fimageproxy.php?img=&key=c723ef59fd17d18f

Edited by BMW2002pnw
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  • 2 months later...

I've been slowly chugging away, cutting out rust and filling it back in


center exit exhaust is much cooler


I cut out the old gas pedal mount (because it was rusted) so I decided to make a whole new aluminum pedal with a door hinge


FLARES!!!!! the passenger side rear fender was hammered and all the other ones were shaped mostly out of bondo


This is what I'm shooting for wheel/fitment wise but I'm thinking something around porche racing green for color


Anyone know how 16x8 et0 are fitment wise?

Edited by BMW2002pnw
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On July 29, 2016 at 6:50 AM, 72_02 said:

Such a good job on the rust! What brand of epoxy primer did you use, and how did you apply it?


I'm looking to sand to metal and would like to lay down decent primer before anything else.

It's lusid technologies north star black epoxy primer and I sprayed it on. That's the way to do it, I wish I had gone to bare metal but I'm on short time frame

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  • 2 weeks later...

I've got all the fenders cut out and the rears welded up, both the front flares are mounted and the rears I need to do some Bondo work around them so they'll fit nicelyimage.jpegimage.jpegimage.jpeg

I decided to use riv nuts so I can take them on and off if I want and also I like the look of the button head Allen key bolts


Edited by BMW2002pnw
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  • 11 months later...

I've been really busy and keep forgetting to post updates, I've been back from school since May but I've just been working and trying to finish my car. Anyways, here's the updates


Airdam is on and primed


I am very tired of sanding... I have sanded every square inch of this car multiple times and very over it


Here's the color, really stoked on it. Looks amazing in person


I got the jams and under the hood/trunk painted, I didn't paint the engine bay since its green and I don't really have time to attempt to paint it right now, May do it seperate down the road.IMG_1219.thumb.JPG.1e5a9300507c5d7544751a7f87ba17c6.JPG

Completely cleaned and prepped for paint this last weekend and tonight, Then been working on masking... which is a gigantic pain in the ass for those of you who haven't done it, mostly because I've been waiting almost 5 years and am getting very excited. I also welded in the parts of the trunk that had rusted out and got the new non leaking gas tank in as well as the bottom of that center frame piece in the trunk, my welding skills still are pretty bad though and I didn't take any pictures which is probably for the best.

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