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Thread: Koza's 318iS

  1. #31
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    Strippin continued, I removed doors, all windows, sunroof panel, mechanism and the sunroof tray looked rusty inside so I cut it out as well. I decided to leave the wiring loom in the car, just wrapped it and tied, probably not the best decision, but saved me some work





    offside wheelarch/battery tray needed work



    rot cut out





    new battery tray made





    I've done some stitch welding around the strut towers as well


  2. #32
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    Moving on to the front of the wheel arch







    I used the 'weld through primer' in areas that were going to be closed up and not possible to paint after welding





    that's the right wheel arch done including some stitch welding


  3. #33
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    Next job was to fix the drivers foot well



    I made some new parts, the smaller one you see was made of 2mm steel and includes a bracket to allow for plastic wheel arch liner bottom mounting after the box was removed from the corner of the floor as I wasn't gonna replicate it - I think it's main cause of rust in this area



    Again used some of the weld thru primer



    job done




  4. #34
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    Tasty fabrication

    Sent from my SM-G920F using Tapatalk
    1990 E30 316i M42B18 Matte Black 2 Door
    1995 E34 518i Techno Violet Metallic Saloon

  5. #35
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    kenoc is offline Premium Member (Site Supporter)
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    Great work, thought you stated earlier that you weren't experienced in welding?
    Looks good to me.
    72 Chevy C10 Stepside 350
    90 318is Sold
    02 530i Touring Sport
    83 E21 320/6 - Sold
    84 316 - Sold
    85 528i - Sold

  6. #36
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    Nicely done Michael, looks really well and coming along. Keep up the great work.
    Hope this helps,
    Cab



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  7. #37
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    Mar 2013
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    Yeah I haven't welded much before, I learned working on the car and we build a trailer with my mate as well so that gave me lots of practice too. I'm not 100% happy with my welding but it's ok.

    Good few of the body screws broke of during strippin, these are the heat shield ones fixed



    bottom of front chassis leg








  8. #38
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    Mar 2013
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    Moving on the nearside wheel arch, rust, rust and more rust



    front of wheelarch rotten the same as other side, same way of fixing, trying to replicate original to be able to fit the wheelarch liner, new parts made



    ready for welding, always measure twice and clean of all paint



    weld thru primer







    wire wheelin, measurin, markin, cuttin, measurin, cuttin, weldin, grindin...

    I got a donor car, was useful for few cutouts, will be useful when putting my project back together too









    area below fuse box, I started regretting not removing the wiring loom, but I wrapped it and the fuse box in a welding blanket to protect from sparks and heat







    brake pipe hole







    rear of wheelarch/bulkhead/glovebox mounting







    that's the passenger wheelarch done

  9. #39
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    Passenger foot well, same as driver's side, rotten in the corner around the 'not a jacking point box thing'



    jeeez I hate rot



    and love new shiny metal









    passenger seat mounting area, didn't look too bad from top



    I've cut out that much, I wanted to leave the mounting stud in place



    some new metal, the little bit beside the stud is 2mm thick



    the welding clamps were handy





    that's the floor pan done

  10. #40
    Sceptre is offline Premium Member (Site Supporter)
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    Great photos and examples of where the E30 rusts. This car could be described as having no rust (whatsoever) initially. Lots of work in putting it back together but reassuring to know you have a solid car underneath.

  11. #41
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    Yes almost every E30 you see in the ads for sale nowadays is described as little to no rust which in 99% cases isn't true. Also most people don't know what they have until they start diggin. When I bought the car I knew it's a bit rusty and couldn't believe how serious it was after I took everything apart as most spots are hidden.

    Ok, back to the project

    Door sills, started at the nearside





    I cut out the repair piece out of the donor







    I wanted to strengthen the jacking points on the sills so I welded a 2mm thick strip of steel on the bottom lip of the sill, you can see it better on the next picture



    now the rear part of the sill



    to hell with rot






  12. #42
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    The sill on drivers side was a bit worse



    ready for new part



    again donor car was helpful



    ready welded and grinded with the strengthening strip in place



    and the rear





    when working on the other side I tried to replicate the brass welded seams but that didn't go well so I just mig welded them, it won't have the original grooves anymore but I don't really care. This side I just used a section of a sill from the donor car as one piece, so no seam in the middle





    That's the story of the sills. I have a lot more to update. Till then...

  13. #43
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    Thats what i call top class,you could earn a living doing that,its a rare talent to
    Have,well done!

  14. #44
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    Awsome .... keep it going !!!


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  15. #45
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    Mar 2013
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    Thanks for the kind words lads, I don't think I'd like to do that kind of job to make a living thou, mechanical part of the project is much more enjoyable to me, especially fitting shiny new parts

    I just want to share a pictures of my classic car I have in Poland.

    It's a 1971 Polski Fiat 125p, 1300cc

    I bought her some years ago, she was fully restored and is still in very good nick, not driven much and kept in doors of course, every time I'm back home I drive her as much as I get the chance and there's always some little job to do on her which I always enjoy doing. I love the simplicity of the vintage vehicles.





    Going back to the project, I could see some corrosion in the rear corner of the sunroof tray, as already decided to do a full respray I thought I'd be best to cut out the tray and remove all the rust.



    that corner was the worst and looked like surface rust



    turned out badly pitted and slightly rotten through, so I made repair piece using cardboard template











    than I welded up all the holes I drilled earlier to cut the spot welds and after all welding I sandblasted the tray and painted with epoxy primer, I used the weld thru primer around the welding spots which were to be hidden after the tray went back in the car



    the sunroof panel was also badly corroded, it's nearly impossible to find a second hand one that's rust free, I found one on eBay from USA but was quite dear so I decided to try and fix mine



    I separated the two pieces its made of by grinding of the spot welds around the edge





    The upper panel/cover was corroded and slightly pitted, only one pinhole rotten through so welded that. The bottom reinforcing part was bad, I sandblasted it and started by cutting out the rot and making new pieces









    When done it turned out the piece got shrunk and was actually few mm narrower than before, so I cut it and welded small piece in to get back to original size





    I sandblasted the cover and bottom piece, painted with epoxy and weld thru primer around spot welds



    I put some sikaflex windscreen bond around the inner edge of bottom piece and stuck them back together and welded back at the spots where was welded originally



    Unfortunatelly I don't have a photo of ready panel but it turned out good, it took a lot of hours to do but I saved good few hundred euros on new one. It got warped slightly but the panel beater should be able to make it perfect, so should last some long years.

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