BMW 2002 Touring '74 Full restoration project

Got my pistons delivered to the local machinist. He also had some good news for me. He pressure tested the cylinder head on cracks and turns out it's all good to go, no crack!

Yesterday
I got the front calipers back together. I first sandblasted the inside of the old pistons and spray painted them with heat resistant paint.
Afterwards I let the paint cure in the oven. Same thing with the calipers halves since I clear coated these after the cad plating.
New parts laid out, rebuild kit is from Walloth Nesch


And back together!




Very happy with the outcome, definitely a good choose to get these cad plated as well

Got my pedal box back together, fun little project.
After making sure I had all of the new bushes, bolts, and parts, I took it all home and got started with assembling.
Still need to torque everything down and bolt the master cylinder against the box as I forgot to take those bolts with me.


Close up of the pedal box

 

I think the BMW museum will be interested in this one by the time you've finished Martijn    

Simply mind blowing Gentlemen! 👍 😀

Hairyarse said

I think the BMW museum will be interested in this one by the time you've finished Martijn    

Thank you Andy! Haven't done much welding as of lately, still welding/doing rust repairs on the E30..

Golf Cabrio said

Simply mind blowing Gentlemen! 👍 😀

Thanks, Mike!

Yesterday I picked up the engine, cylinder head, flywheel and some other engine parts from out local machinist.
He pressure tested the cylinder head, resurfaced it together with the chain cover and gave it a clean.The engine got first measured up, which told us that one piston had worn down the cylinder over the first oversize.He bored the engine to the 2nd oversize after I found some new Mahle pistons, gave it a hone + new freeze plugs and wash. The engine didn't have to be resurfaced as it was still good. The flywheel also got ground down so we have a nice flat surface for the new clutch disc. I still need to get new bearings for the crankshaft and connecting rods before I can start putting it back together. I'll go with Kolbenschmidt bearings as I can't seem to find the Glyco's. For now I put some more oil on the freshly cleaned and machined surfaces so they won't rust.

After being finally done with welding on the E30, I got started with blasting the in and outtakes of the cylinder head.
Pressing rubber tubes into the valve guide made sure these wouldn't get damaged. I also tape the whole head in duct tape to protect it from glass beads entering the oil/coolant passages. I will still clean the head with some water to be 100% sure there aren't any beads left inside.

is that the B20 head? Some top work being done there mate, keep it up!

Slow & Low said

is that the B20 head? Some top work being done there mate, keep it up!

Thank you for the compliment!
It's a E12 type head, M10 engine.

The B20 head was used in the M10 E30's if I'm not mistaken.

Haven't done as much to the Touring but today I finished cleaning up the valve cover. I also sandblasted the corrosion on top and then glass beaded the cover so there it had a nice smooth finish. I then protected it with some clear varnish.


Turned out great!




Being that the blasting cabinet was now full of glass beads instead of glass grit I decided to blast the rubber bushings for the rear and front springs as they were quite dirty and had some rust particles on them.
This gave it a nice finish. I might treat them with some kind of product so the pores will be sealed.


Also gave the newly purchased coil for the alternator a coat of primer. Still need to find some kind of red/orange paint like original.

Today I cleaned and refurbished the Bosch distributor for the 02.
I started with cleaning the outside and lightly go over it with some scotchbrite. I also cleaned the inner mechanism as it was quite dirty/greasy.
When we plated the nuts and bolts, I took the hardware from a one of the spare distributors that was already missing a few pieces to also get plated.


I then installed the new breaker points and set the correct gap (0,4mm)


I also tried getting the vacuum chamber plated but it did not turn out all that great so I decided to bead blast the one fitted on ours and paint it with some RAL 9006 aluminium color. Aso got the little clips blasted and painted black. I'm pleased with the result.

Next week we are going to paint most the parts for the touring in 2k satin black paint that are now currently sitting in primer after we got these sandblasted previously. We'll be making a small paint booth with some steel tubing.
Since the differential is still assembled, we started on disassembling it. With the help of some brackets and a long breaker bar we were able to brake the big nut on the input shaft loose.
Also the 2 bolts on the output shafts got removed.

Everything disassembled and also removed the old seals.


Teeth on the ring gear, little spiders and input shaft still look great. I don't think we'll replace the bearings as these also look good.


Next thing is to get the hardware plated with a kit to do it yourself. And also cleaning up the housing and bearing housings with the sandblaster and some wirewheels.
Then on to painting!

Today I got the rear diff cover cleaned up and coated in clear. I did paint the little metal vent tube in silver to protect is some more.


After degreasing the inside of the diff so there wasn't any oil left I wire wheeled the outside so remove some of the small rust spots.
I then taped it all up and gave the bare metal spots a coat of primer. The housing is now ready to be painted black. I still need to blast the bearing housings and input flange but ran out of primer.

Looks like Photobucket have hidden your pics? Seems to be a common thing at the mo, I guess they've changed their policies??

Hairyarse said

Looks like Photobucket have hidden your pics? Seems to be a common thing at the mo, I guess they've changed their policies??

Jup.. it sucks.  My golf mk1 thread is also effected by it..
Not sure what I'm going to do.. It'll take so long to rehost all of these pictures..  

As I know that most of my pictures aren't working (still planning on re editing every post)
I decided to already update my build post with some new pictures.

I got the alternator stator sandbasted, primed and painted red. I also received my new rotor. The guy from my local electro workshop told me it was the last one that was available from their warehouse. I got lucky and got the last one





Last week I got the epoxy primed parts fully sanded smooth and primers the bare metal spots again. Fully ready to get painted with2k black satin paint.

Finally got the remaining parts painted black. After making a spray booth with some square tubing and plastic foil + a little rack to hang to parts on I got started with painting. Second time using a paint gun, turned out pretty good if I say so myself

I'll probably give it a second coat when it's all dry as I laid it not too tick to avoid runners + there are a few small spots that I didn't quite fully cover with paint.



Radiator, I did not paint the little cooling fins as I still need to bend some of them back into shape. I'll spray these with some heat resistant black paint later on.


Air filter housing lid


Diff + driveshaft parts


Brake booster

Great work as always!

I like your spray booth too  

Hairyarse said

Great work as always!

I like your spray booth too  

Thanks Andy!
It came out pretty good for only some steel tubing and cheap plastic foil. the painting rack is also very handy because of the 2 horizontal tubes.

After buying another liter of 2k black satin paint we got the second layer on the parts.
There were a few spots that had some overspray so I decided to lightly sand these parts first so I could get a smooth finish when applying the second coat.

As far as I can tell it came out very good, especially for only using a (cheap) spray gun for the third time.

my brother and I also started disassembling the startmotor for the engine. We'll probably give this only one coat when doing the underside of the air filter housing and lid as I haven't painted those yet.


The stator still looked good as does the stator, we'll just give them a clean an reassemble them back after painting the housing.