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  #31  
Old 23-11-2016, 11:36 AM
koza koza is offline
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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

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  #32  
Old 23-11-2016, 11:58 AM
koza koza is offline
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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

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  #33  
Old 23-11-2016, 12:14 PM
koza koza is offline
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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



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  #34  
Old 23-11-2016, 02:44 PM
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GOR///M GOR///M is offline
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Tasty fabrication

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  #35  
Old 23-11-2016, 02:58 PM
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Great work, thought you stated earlier that you weren't experienced in welding?
Looks good to me.
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  #36  
Old 23-11-2016, 03:48 PM
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Super4 BMW Super4 BMW is offline
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Nicely done Michael, looks really well and coming along. Keep up the great work.
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  #37  
Old 24-11-2016, 11:08 AM
koza koza is offline
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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







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  #38  
Old 24-11-2016, 12:03 PM
koza koza is offline
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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
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  #39  
Old 24-11-2016, 12:26 PM
koza koza is offline
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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
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  #40  
Old 24-11-2016, 02:27 PM
Sceptre Sceptre is offline
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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.
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  #41  
Old 25-11-2016, 10:34 AM
koza koza is offline
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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





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  #42  
Old 25-11-2016, 10:47 AM
koza koza is offline
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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...
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  #43  
Old 25-11-2016, 01:18 PM
george/glanmire george/glanmire is offline
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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!
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  #44  
Old 28-11-2016, 10:47 AM
firu1 firu1 is offline
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Awsome .... keep it going !!!


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  #45  
Old 29-11-2016, 12:14 AM
koza koza is offline
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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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