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E30Rossi's Full Build - Overhaul - 5 Lug - Bay Shave - M54 Swap (Pic Heavy)

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    Originally posted by Mike36 View Post
    This gonna be good!
    Thanks for the confidenceπŸ™πŸ» Hope so after all this work
    ​

    1989 BMW ​325i - M54B30 Swap in Progress
    IG : e30rossi
    Montreal, Canada

    Comment


      Click image for larger version

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      Continued with the bodywork this past weekend, seems like it never ends

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      Driver side got a coat of primer to see any imperfections since it was 16 different colours

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      A little bit of primer goes a long way!
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      Not perfect but pretty proud of where's it's at since I've never touched body work ever before this
      ​

      1989 BMW ​325i - M54B30 Swap in Progress
      IG : e30rossi
      Montreal, Canada

      Comment


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        Ran out of primer, but trying to tackle one area at a time

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        Been avoiding this corner since the beginning, definitely the worst part of the engine bay
        You'll see why soon enough

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        Started working on the firewall, I cut off all the studs for the plastic nuts that hold the oem insulation since that won't be used anymore
        A few problem areas but nothing major and mostly hidden by components

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        I was so tempted to remove the fusebox to get to this corner but it's sooooo much work for what I'd get from it!
        I will have to work around it, at least it's has some flexibility to move around!

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        Figured I'd paint the top of the fender supports with the body colour while I'm painting
        ​

        1989 BMW ​325i - M54B30 Swap in Progress
        IG : e30rossi
        Montreal, Canada

        Comment


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          Laid on a coat of undercoating on the front part of the trans tunnel so it would be ready for paint as well!
          Got to lay in there to get to the shifter area since I removed the undercoating I applied a few years ago after never drying properly

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          Keep dreaming of seeing this thing with the suspension and wheels back on, laid back down on the ground

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          So glad I removed the core support, working in here is 100x easier

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          Driver side got some finishing putty and a coat of primer, and now it's pretty close to perfect in my eyes
          Will be applying seam sealer to all the seams and the front welds which will be hidden
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          So..... I've been avoiding this spot since day one
          There was a small rust hole, and I previously glued in a piece of metal with JBWeld while I redid the rest of the car
          knowing it would be temporary and Id take care of it properly once I got in the engine bay repairs
          I hit this area with the wire wheel in the wheel well, and it just grew to the point where I had to cut it all out
          The part that stresses me the most is the other side of that hole in the back is inside the car behind the dash
          I have access to it, but It will be very sketchy to weld without removing the dash.. I guess I will find out this week how that goes!
          Wish me luck
          ​

          1989 BMW ​325i - M54B30 Swap in Progress
          IG : e30rossi
          Montreal, Canada

          Comment


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            After hours of finding imperfections, finishing putty, sanding, and repeat
            I finally was able to hit the engine bay with a thick coat of high build primer
            Besides that one corner I need to address, overall it's looking pretty ready for paint!

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            Ran out of primer on this side so gonna have to finish the coat once the battery tray is done

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            There's some small holes under the blower motor, but this is where I draw the line.
            Cleaned it up as much as possible, hit it with some rust converter
            It's going to be completely covered either way

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            Started making the patch piece, going to cut a little further out and get this welded in this week, and that concludes the engine bay repairs 100%

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            Little before / after of the last 3 months of work on every single weekend to get to this point
            Felt like I wasn't making progress but sometimes looking back makes you realize

            Next 3 months will be dedicated to tearing the motor apart ( Yes I decided why not while we're here)
            Rebuilding it and replacing whatever needs to be replaced.
            Any recommendations of what to replace would be appreciated!!
            Just talking about engine interals here, because I already have every single sensor and part around the engine brand new
            ​

            1989 BMW ​325i - M54B30 Swap in Progress
            IG : e30rossi
            Montreal, Canada

            Comment


              Originally posted by E30Rossi View Post
              The part that stresses me the most is the other side of that hole in the back is inside the car behind the dash
              I have access to it, but It will be very sketchy to weld without removing the dash.. I guess I will find out this week how that goes!
              If you can, get a bigger piece of aluminum or copper on the dash side. Can hold it in place with strong magnets. It helps to block some of the hot bits from coming through. Just did this last weekend when welding into the trunk from the rear wheel tub.

              Try to have someone on fire watch if possible.
              And keep water & fire extinguisher BESIDE you while welding.


              Originally posted by E30Rossi View Post
              Little before / after of the last 3 months of work on every single weekend to get to this point
              Felt like I wasn't making progress but sometimes looking back makes you realize
              Doesn't even look like the same car anymore!

              I love reading/posting build threads for this reason, makes you realize/helps you remember how much work went into it.

              Comment


                Originally posted by Panici View Post

                If you can, get a bigger piece of aluminum or copper on the dash side. Can hold it in place with strong magnets. It helps to block some of the hot bits from coming through. Just did this last weekend when welding into the trunk from the rear wheel tub.

                Try to have someone on fire watch if possible.
                And keep water & fire extinguisher BESIDE you while welding.



                Doesn't even look like the same car anymore!

                I love reading/posting build threads for this reason, makes you realize/helps you remember how much work went into it.
                Thanks for the tip! I think we have a fire blanket at the shop and I will definitely be ready with everything I have for prevention just in case!

                I appreciate it! And I think it was the best idea to go back and post my journey since day one just for myself to be able to go back and see all the progress! Also pretty cool when other people can appreciate and benefit from it!

                ​

                1989 BMW ​325i - M54B30 Swap in Progress
                IG : e30rossi
                Montreal, Canada

                Comment


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                  Welded that piece in without lighting the car on fire! Lots of precautions were taken and definitely stressed about it the entire time
                  but we made it through!! Happy that I was able to cut out most of the badly rusted areas on the car now!

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                  Grinding down welds to blend it in more

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                  After welding that part, there was a pretty large gap under from all the rusty metal being cut out
                  So we proceeded to cover in this section completely in the fender well

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                  More putty, sanding and paint prep!

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                  Laid another coat of high build primer
                  Very close to being ready for paint now!
                  It's not perfect in some places, but as I've said it's my first time and I'm learning as I go!
                  ​

                  1989 BMW ​325i - M54B30 Swap in Progress
                  IG : e30rossi
                  Montreal, Canada

                  Comment


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                    Very annoying trying to work around the fusebox, but the amount of work involved in depinning it is not worth the
                    trouble in my opinion, so I will have to find a way to paint with it there

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                    Looking smooth for the most part!
                    There are minor imperfections here and there that I will try to address one last time
                    All the seams and edges will get seam sealer, so that will help

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                    Driver side looks good! There's areas like the frame rail and the part that will be covered by the core support
                    That I've tried and tried to make perfect but realized they will never be visible and I was driving myself crazy over it

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                    Some more sanding to do in this corner as it was the last area worked on
                    Will get to that this week before paint!

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                    Hadn't touched the corner behind the fusebox either so this got some putty and primer

                    I was offered to get the engine bay painted by a professional painter at the shop this coming weekend
                    I had no choice to take up the offer, so stay tuned for paint very soon!!
                    I'm super excited to conclude this part of the build and move on the the motor!
                    ​

                    1989 BMW ​325i - M54B30 Swap in Progress
                    IG : e30rossi
                    Montreal, Canada

                    Comment


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                      Final prep before paint this weekend!

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                      Taped all the areas for seam sealer

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                      Started to apply seam sealer
                      Definitely takes some practice!
                      I learnt by trial and error than you can pass your finger through once after applying and that's it
                      Second time ruins the texture. Oh well, live and learn

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                      ​

                      1989 BMW ​325i - M54B30 Swap in Progress
                      IG : e30rossi
                      Montreal, Canada

                      Comment


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                        Finished seam sealing, and sanded down the primer to be ready for paint the next day!

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                        Some places worked better than others but it was a learning experience!

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                        ​

                        1989 BMW ​325i - M54B30 Swap in Progress
                        IG : e30rossi
                        Montreal, Canada

                        Comment


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                          The day FINALLY arrived!

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                          Looking like glass!

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                          Super happy with how new and glossy this ended up looking!

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                          Now the engine bay looks too good, makes the rest of the car look dull !!

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                          ​

                          1989 BMW ​325i - M54B30 Swap in Progress
                          IG : e30rossi
                          Montreal, Canada

                          Comment


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                            Seeing this made the last 3 months of work all worth it! So stoked on how it looks

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                            Also painted the rad support, ready to go back on !

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                            Blower motor cover got a coat, going to blend in super well!

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                            Last but not least, booster will look so much better colour match vs. the aluminum x3 finish
                            ​

                            1989 BMW ​325i - M54B30 Swap in Progress
                            IG : e30rossi
                            Montreal, Canada

                            Comment


                              Very nice very nice, now comes the easy bit
                              sigpic

                              (clicky on piccy to get to thread)

                              Comment


                                Nice job with the seam sealer. Came out looking great after paint!

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