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Old 12-17-2016, 03:07 PM   #391
dvallis
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Patching the firewall

I put my nephew to work making a template for the firewall sheet metal patch.



Here's the work in progress. Will get more screws, slight bends etc. I'm liking it. After we shoot it with paint will look OEM. It's mostly hidden by the engine anyway.

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Old 12-22-2016, 07:41 PM   #392
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Finishing the firewall

Firewall patch with more bends, holes, tabs etc. Using 3M double sided industrial rubber tape to seal the patch.



Patch in place and looking good.

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Old 12-22-2016, 07:52 PM   #393
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Wings and things

Of course, a simple day bolting on the wing turns into a freaking adventure.

Trunk is curved.



Wing is flat. (Made for an E30 M3 trunk) Oh joy.



Instead of cutting down the front of the wing, I decided to build up the rear. Started with a cardboard mold.



Filled the mold with MarGlass. Love this stuff. Cures in 15 minutes and it's hard as hell.



My dustless (sort of) sanding rig. Shaping the MarGlass with a sanding block.



After a lot of sanding, the wing base fits the trunk.



Making the trunk brackets.





Finally all done. Sits on the trunk nice and solid. Needs a bit of bondo and sanding to be ready for paint.

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Last edited by dvallis; 12-23-2016 at 05:59 PM. Reason: typo
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Old 12-23-2016, 05:58 PM   #394
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Das Beast metal shop

Revisiting the interior metalwork today. This stuff takes a LONG time to get right. Had to (1) Invent a sub-structure for the rear deck, (2) Figure out how to connect rear deck and rear bulkhead, (3) Trim everything so it fits right, (4) Hunt for all the materials at Lowes and (5) Do it !

Of course there are always issues. Drill didn't fit here. Had to improvise with the Dremel.



The hardest part was fitting my body in HERE. @#$@#$!!!!! I am a big guy. Getting into the back seat and contorting myself around the roll cage was ..... interesting.



Six hours later, here's the end result. Very satisfying to have it look this good, considering the total lack of sophisticated metal working machinery.







Getting close to paint time. Going to sort the front end next.
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Old 12-29-2016, 10:07 AM   #395
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Love the build man, got me motivated to get a bunch of things done on my build that i had been putting off. Keep it up!
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Old 12-29-2016, 11:21 AM   #396
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Originally Posted by dvallis View Post
The hardest part was fitting my body in HERE. @#$@#$!!!!! I am a big guy. Getting into the back seat and contorting myself around the roll cage was ..... interesting.
Im 5'6" and my roll bar is fairly similar to yours and it was a nightmare. I cant imagine how much of a pain it mustve been for you.

My wife came down to visit me while I was struggling in the back and snapped this pic of me a few weeks ago

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Just keep pushing it in... when you think you can't push it in any farther, push harder.
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-2008 C350 Sport... the daily?
-1984 BMW 318 with Aluminum M52B28 and other goodies... cant be killed!
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Old 01-11-2017, 08:48 PM   #397
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Das Beas Is Back

Now that the freaking arctic freeze is over we are back to work. Once the temp stays over 70 for a week it's paint time.

We're fitting the fiberglass hood tonight. High capacity double pass radiator needs to drop "1 so the fill cap will clear the hood.



Most guys use 4 hood pins. However, at racing speeds the front lip of a lightweight fiberglass hood will lift. We're starting with a hood pin dead center to prevent this. Will drill the BMW logo and fit over the hood pin when its all done. Should look very cool.

Don't screw up drilling the hood.



Center pin mounting in progress.



I like it.



Front left and right pins are easy.



Front pins mounted.



We used some caulk on the side pins, placed the hood then drilled at the caulk marks.



And here's the final result. Looking very Race Car. Still needs rear pins but we'll finish those next time.

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Old 01-12-2017, 07:11 AM   #398
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That radiator looks niiiiccceeee.
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Old 01-15-2017, 05:55 PM   #399
dvallis
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Almost the end of Body And Paint

Man. Body work is totally OCD. Finally on the last steps

Apply guide coat. Shows all the high spots, rough patches and voids



Fix spots with glazing putty and more 400 grit sanding. Repeat ad nausea.



By the time you're done the guide coat is totally sanded off. Repeat for all fenders and body.



We're ALMOST ready for paint !!!!!!!

Did some other minor stuff. Here's something cool. Since the trunk now has a big ass wing attached, we're going to want extra security for it not to go flying open. Trunk pins!



Sexy! Will screw the final hardware on after paint.

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