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

[D.martijn]

Yesterday I got my parts back from the plater. I also gave him another batch of other parts to plate. This will make it easier to sort everything.

 

All the parts that need to get sorted

 

Box full of new nuts, bolts and washers

 

Car parts, hubs, rods, brackets...

 

Some more specific nuts and bolts

 

And some white plated parts, mostly for the alternator. The plates for the horns didn't turn out great, looks like these weren't steel..?

I'll go ahead an blast these again and just paint them silver

 

And the sorting begins!

 

By putting the bolts on their head, it's easy to put them together length wise

 

All nuts, bolts and washer in bags

 

And started sorting the more specific nuts and bolts.

By printing the pictures I took when sandblasting the parts it's very easy to sort everything!

 

 

Gotta love details like these

Washers for the horns with their Hz rating

 

SWF (now Valeo?) marking on the wiper arms

[D.martijn]

After sorting the plated parts (at home) I went to the workshop and cleaned it up a bit since all the workbenches were full of glass from blasting.

 

When my brother arrived we looked into pressing in the bushings, with some vaseline and the bench vise this went very easy.

 

And done.

 

I also test fitted the parts on the rear beam but I don't have any pictures of this.

[D.martijn]

Finally finished welding the passenger side floor.

 

Final piece was this panel I made out of some flat sheet by using the remainings of the original floor and based on the replacement panel from Walloth Nesch for the driver side floor

 

And welded in

 

Still need to grind down the welds and clean up the panels. On to the A pillar!

 

Also pressed in the bearings on the rear arms and poured some Por 15 inside of them. (Also did the rear beam)

Got myself a nice bit pot of bearing grease

 

With my fingers I applied grease inside the grooves, making sure there was grease coming out of the bearing cage on the other side of the bearing. I then packed the other side of the bearing and tapped it in place with a big socket.

 

When installing the other bearing, BMW workshopmanual states to apply 35g of grease on the tube that sits between the bearings. It also says to measure the distance, I assume to make sure that the tube wont cause pressure on the inner bearing race?

You then add another washer and then finally tap the bearing in place.

[D.martijn]

Cleaned up the transmission

 

After I took this picture I noticed oil seeping out of the vent plug, decided to drain the transmission until I replace the seals. 

The oil that was coming out was still very good! Looked almost new 

 

Removed the center bearing from the drive shaft.

Since I do not have a big enough tube to slide over my wrench, I welded 2 short plates on a long piece of square tubing and drilled a hole through it so I could attach the wrench to the tube. Worked out great!

To make sure the drive shaft wouldn't spin, I use a steel L-profile and bolted the drive shaft to it, I then backed the car up on the L-profile using some wooden blocks.

 

The wrench

 

Both pieces removed, I'll first paint the driveshaft black before putting a new center bearing on.

[Tommy]

On 17.3.2017 at 9:14 PM, D.martijn said:

When installing the other bearing, BMW workshopmanual states to apply 35g of grease on the tube that sits between the bearings. It also says to measure the distance, I assume to make sure that the tube wont cause pressure on the inner bearing race?

You then add another washer and then finally tap the bearing in place.
 

The measurements are made to choose the correct thickness shim to create just the right tension to bearings. The shim is what you refer as washer under the bearing. If you didn't mix the parts from side to side you are fine. If you're not sure you may still be fine but when the stub shafts and hubs are installed and the big nuts tightened check that both sides feel the same. If one feels tight and another loose it's not good.

[D.martijn]

1 hour ago, Tommy said:

The measurements are made to choose the correct thickness shim to create just the right tension to bearings. The shim is what you refer as washer under the bearing. If you didn't mix the parts from side to side you are fine. If you're not sure you may still be fine but when the stub shafts and hubs are installed and the big nuts tightened check that both sides feel the same. If one feels tight and another loose it's not good.

 

I've measured the lenghts on both axles like the BMW workshop manual states.

And by doing so you make sure ylu got the correct thickness of washer and it was good on mine.

 

Before installing the bearings I also measured the big tube and shims and both measured the same.

So it should be good.

[D.martijn]

Haven't done much since last time since I'm currently welding on my E30. The heater core valve started to leak so I had to remove my carpet which meant removing the whole interior. I then discovered some rust which I'm now repairing.

 

Got my second batch of plated parts for the Touring. Mostly interior parts and some stuff we forgot the first time.

 

 

Brake caliper

[D.martijn]

Got started on assembling the heater box again. Still need to get some new foam for the little flaps.

All the new parts pictured together

 

Controls

 

Also painted the big flap in black

 

I didn't revit the plated parts as it'll be easier to attach the foam

 

Also got the windscreen washerpump back together, gotta love these little details

[D.martijn]

Blasted my heater core and painted it black. I also attached new foam to the heater core and flaps inside of the heater box.

 

"Before" and after shot with an other heater box I had laying around. Turned out great!

[D.martijn]

Got the new pistons for my engine. The lower compression 2nd oversize pistons aren't available anymore from BMW/Mahle.

I stubbled by coincidence on a still sealed set of Mahle pistons partno 0820402. By searching the number on google it confirmed these were the lower compression pistons + it crossed referenced with the BMW part no.

 

 

 

 

 

The box also had a little paper inside with a number/code of who packaged the pistons

[02Les]

On ‎3‎/‎15‎/‎2017 at 9:44 AM, D.martijn said:

Yesterday I got my parts back from the plater. I also gave him another batch of other parts to plate. This will make it easier to sort everything.

 

All the parts that need to get sorted

 

Box full of new nuts, bolts and washers

 

Car parts, hubs, rods, brackets...

 

Some more specific nuts and bolts

 

And some white plated parts, mostly for the alternator. The plates for the horns didn't turn out great, looks like these weren't steel..?

I'll go ahead an blast these again and just paint them silver

 

And the sorting begins!

 

By putting the bolts on their head, it's easy to put them together length wise

 

All nuts, bolts and washer in bags

 

And started sorting the more specific nuts and bolts.

By printing the pictures I took when sandblasting the parts it's very easy to sort everything!

 

 

Gotta love details like these

Washers for the horns with their Hz rating

 

SWF (now Valeo?) marking on the wiper arms

The Horn Washers are interesting. I guess I must have missed those on my Touring rebuild, but, I did notice the Horn Brackets. There were 3 pieces per bracket and also stamped for either the lo tone or high tone.

Edited April 22, 2017 by 02Les

[D.martijn]

50 minutes ago, 02Les said:

The Horn Washers are interesting. I guess I must have missed those on my Touring rebuild, but, I did notice the Horn Brackets. There were 3 pieces per bracket and also stamped for either the lo tone or high tone.

 

Hmm, I don't seem to have those marked brackets. Are your horns also Bosch? Or Hella?

Both my horns had 3 rectangular sheet metal plates (painted in black) bolted to them.

I don't have a picture of them, they are currently sitting in primer awaiting to get painted with some black 2k epoxy

[02Les]

3 hours ago, D.martijn said:

 

Hmm, I don't seem to have those marked brackets. Are your horns also Bosch? Or Hella?

Both my horns had 3 rectangular sheet metal plates (painted in black) bolted to them.

I don't have a picture of them, they are currently sitting in primer awaiting to get painted with some black 2k epoxy

There were 3 to a set (per Horn) but only one per set had the stamping on.

My Horns are actually Lucas (British and LOUD) but I have a few other correct Hi & Lo horns (Hella, I think). All of them have these metal mounting plate sets.

[D.martijn]

9 hours ago, 02Les said:

There were 3 to a set (per Horn) but only one per set had the stamping on.

My Horns are actually Lucas (British and LOUD) but I have a few other correct Hi & Lo horns (Hella, I think). All of them have these metal mounting plate sets.

 

Oh oke, I get it. Does you horns looks like.. uhm.. horns? Or are they also round a round shape. I'll try to make some pictures of them later today if I don't forget.

[02Les]

4 hours ago, D.martijn said:

 

Oh oke, I get it. Does you horns looks like.. uhm.. horns? Or are they also round a round shape. I'll try to make some pictures of them later today if I don't forget.

The ones I have, even the Lucas ones, are shaped like a horn (number 1 in the attached pic).