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

[E30Rossi]

love the updates , keep em coming ! you almost there

thanks! They will definitely keep coming until i'm done! I wish I was almost there but this is just the beginning because i have the whole motor and swap to deal with after the bodywork😂 lots to go but super excited!

[R3VM3UP]

How do you get the fuse box apart on these cars with enough slack to get in an depin stuff? I have several circuits I need to clean up after removing things.

[QuiqueUy]

love the updates , keep em coming ! you almost there

[E30Rossi]

Bodywork is definitely an art and requires patience. Looking good so far!

I always knew this, but actually doing it is a whole other story and now anyone that does this on a daily basis has all my respect 😂
hopefully by the end of this weekend, it will be all on primer and ready for paint! I've been stacking parts up for the swap but Im itching to start piecing it together!

[Panici]

This past weekend, I learned how to use putty, and I am convinced this is the last time I'll ever do this, SO MUCH SANDING

Bodywork is definitely an art and requires patience. Looking good so far!

[E30Rossi]

This past weekend, I learned how to use putty, and I am convinced this is the last time I'll ever do this, SO MUCH SANDING


Apply putty, sand, apply putty, sand, apply.....


Took the core support into the sandblast cabinet and removed any paint / undercoating left
Will paint this at the same time as the engine bay as well


Still learning, did a few coats of putty and sanding, threw on some high build primer to see how forgiving it is, and found lots of little imperfections
Started sanding down the imperfections, but lots to go on this! First time doing any sort of bodywork so big learning curve


Trying to keep my eye on the final result, because this is taking a lot longer than I planned, and I need to get to the swap part ASAP!

[E30Rossi]

Mounted with 4 bolts on each side



Added some more reinforcement to places that were flimsy after removing the core support


Back to where it belongs, contrary to a lot of opinion, with the 8 bolts, it's super strong

[E30Rossi]

Same thing on the other side


Scraped off all the insulation of the blower motor cover, going to paint this piece with the engine bay
Also removed all the studs in the way of the 318 wire harness cover


Lining up to drill holes


Looking more like a car again

[E30Rossi]

Quick test fit to make sure everything lines up!


End plates welded on



Rivnuts installed, going to be super easy to remove the core support!


Added some reinforcement to the rad brackets since they don't hold onto anything anymore

[E30Rossi]

More updates!

Started working on the removable core support. It was pretty banged up on the driver's side from a previous accident
Made the decision on using this one rather than spend the 500$ on a new one.. Gotta make cuts or else it never ends

The bottom section was pretty rusty and when I drilled the holes for the skidplate, it wasn't pretty, so we cut it out completely and replaced with some sheet metal, fully welded to support the skidplate

Plated off the end sections that were open after cutting it off the car, and made brackets for the mounting points

[E30Rossi]

Cleaned up the steering joint assembly to get ready for when the bay is painted!
Also cleaned up the quick disconnect fuel line that came with the M54, hopefully it will be long enough to use, one less thing to buy!


Test fitted the engine arms that came with the swap, which I recently found the person that makes them from Estonia
The internet makes the world such a small place!

Everything seems to line up good! Can't wait to put this all together!!



Making adjustments to the removable rad support since it was a little bent from a previous accident
Going to be working on making the mounts for this soon!


Took some time to clean all the gunk off the inside of the valve cover this weekend
This is a horrible job to do, any products or advice would be greatly appreciated!!

[E30Rossi]

Yet another order arrived!

-M3 Wiring Harness Covers
-Driver Headlight Cover
-Aluminum Waterpump Pulley
-Aluminum Power Steering Pulley
-3.5 Bar Fuel Pressure Regulator
-Heater Pipe
-Oil Filter Kit
-Brake Line Holders

Getting a pretty big stockpile of parts now! Budget going out the window real quick!! When does it not?


Fully committed at this point, removed all the ABS wiring completely from the fusebox and harness, don't want think lying around if they will never be used again



Also removed the car starter/alarm that was installed a long time ago (2004) and is outdated
Lots of mess removed from under the dash, I will sleep better now



Mocking up the DBW Pedal to see what has to be done, Need to order the bracket it sits in



Luckily the swap came with this harness adapter already! Not sure where it's from, but the instruction have a link to r3v so im guessing a member here?

[E30Rossi]

Don't know. It's possible if it's a late or transitional car, it seems BMW doesn't make multiple body harnesses for different option levels and there are pigtails for things that sometimes don't exist in a given car. There are no other 6 hole connectors that I know of under the dash of an E30.

Definitely makes sense! Just going through all the wiring and want to be sure what goes where! Thanks for the insight

[varg]

So this would be present on a non-airbag car? I guess ill just disregard those connectors then! Thanks!

Don't know. It's possible if it's a late or transitional car, it seems BMW doesn't make multiple body harnesses for different option levels and there are pigtails for things that sometimes don't exist in a given car. There are no other 6 hole connectors that I know of under the dash of an E30.

[E30Rossi]

This might be your orange connector (C240)

So this would be present on a non-airbag car? I guess ill just disregard those connectors then! Thanks!