2nd e30, 87 Lachssilber Revival

[Reichart12]

Had a baby about a month ago so progress has slowed immensely. But I was able to tinker through fixing the bottom of both fenders. The rust was bad where they bolted to the car but luckily didn't spread too high up. Cut that out, weld in a replacement panel from Valcas, and I'm good to go. Well almost. Some light hammering to get them smooth and final fitment check once I fix the front corners of the car.

Not sure what's up next. I started the rockers but I expect that to take awhile to get through. Also may have picked up some extra epoxy resin with my eyes on the roll of carbon fiber I have stashed in the corner. And eventually the rear subframe needs to come down but that's where I have my jack stands positioned for now. Lots to do.

As always, don't forget to check out the YouTube channel too! https://youtu.be/0Tgd7Nwg-xk

[Reichart12]

I see you are getting better on welding job. Keep up with the good work.
Are you going to paint e30 yourself?

Thanks!

I've tossed around some ideas of paint but still not sure at this point. I think a full tear down would be needed for a worthwhile paint job and I'm not ready for that yet. Maybe a short term wrap or I'll paint match spray can the panels I've welded for now.

[e30m3s54turbo]

I see you are getting better on welding job. Keep up with the good work.
Are you going to paint e30 yourself?

[Reichart12]

The next work on the to-do list was a differential upgrade. I had found a 4.10 LSD on FB marketplace not too far away that really called my name. Quick drive and it was mine! The plan was always to just clean it up and slap it back in the car. Obviously, in the middle of rust repair, I knew I wouldn't get the chance to feel the difference in driving any time soon but still figured this is a need to do item for later.

Anyways, removal actually went better than I expected. My subframe is still in the car and for the most part I was able to get the few bolts loose. However, one piece of the subframe did come out with that diff, haha! Looks like after all this for the gas tank and diff removal, the subframe needs to come out anyways. Stay tuned for that.

With my 2.93 diff out, I transferred that rear cover over to the new to me 4.10 and began the clean up. The casing was already in better condition but some wire brushing and chemical treatment it was looking better. I slapped a couple coats of POR15 rust preventer on and called it good. The flanges are still crumby and the internals are not refreshed but again, that'll be for another time if needed. The diff is now off to the side of the garage ready for install, hoping to be in the late summer/early fall. Try to hold me to that.

Old



New



Together, old in front



Internals



Trying to clean more



Finished product

[Northern]

The trunk pockets are my worst nightmare on these cars. So much shit going on and it's an exterior panel so you feel compelled to make it look good. Good job

[Reichart12]

Not bad! That similar corner was where I started on my Alfa when I underwent the rust repair. It came out pretty good from here!

Thanks, I remember a bit about your videos on it and the amount of layers of metal there.

Great work on a tricky area- so many pieces land together there, it's definitely a puzzle!

Ha! A puzzle is a good way of putting it.

wow that's impressive

Thanks!

[82eye]

wow that's impressive

[AWDBOB]

Great work on a tricky area- so many pieces land together there, it's definitely a puzzle!

[2mAn]

Not bad! That similar corner was where I started on my Alfa when I underwent the rust repair. It came out pretty good from here!

[Reichart12]

Ok, another big repair. Some mistake made, some rust cut out, and a bunch of new metal going in. Going to let the photos do most of the talking. It was all so rusty, I didn't really have a reference to work from. I did order the late model battery box so I had to do some cutting and winging it. Definitely could have made this job a ton earlier if I had the proper fitting parts. Anywho, it's in now and I just have some final pinhole filling, leftover weld grinding, and some seam sealing/undercoating to put back on. Done for now. Will do that stuff at a later point. Also still need to find out how to add the battery tray and secure all of that.

https://youtu.be/JlNTn9PLEsc

[Reichart12]

Status update: the car is still rusty. But now at least with one area a bit less rusty. I did start on replacing the battery box area metal but got distracted by my rusty tow hook. Figured it was easier to replace now while I had the whole corner opened up. I'm actually surprised no replacement versions were available. All I could find online were screw in strap type versions. Looking back, welding in a nut for those to attach to would have been way easier.

Anyways, I started cutting and metal (read:rust) started disappearing.

I bought a 3' section steel rod to make my tow hook out of. Turns out I don't really have rod bending tools so that shape didn't turn out perfect but I think a strap or clamp can still be attached to my tow hook if need be. It was interesting to see how many different layers of metal came together to form the rear of the car. I probably didn't remove or attach everything in the correct order. I do feel good about it being a sturdy repair though. Let's just hope it can stay rust free for a few years. Picture time now for all you visual learners.

https://youtu.be/UigL954uuHc

[Reichart12]

Wow this kicked my butt for how few bolts needed to come off. Gas tank is off! Not sure if I posed here about it and too lazy to check but in 2020 when living in California, I thought my gas tank leaked. At the house I parked on a slight slant and I thought the gas leaked out of the seam on the driver side. A local shop changed a few hoses and the filter in that area. But I never felt good about it. Decided to never fill the tank above halfway and just lived with it. Well now that I'm doing the rust repairs and just continually ripping things out, out comes the tank. And yes, it definitely leaked out the side as I dropped the tank unevenly and sloshed the fuel to that side. Would have drained the fuel first but rounded out the drain plug. Planned on buying a new tank so who cares. Dumped the remaining gas into a bucket, let the rust particles settle and move that to my gas jugs for the lawn mower. Check out all those particles that settled out! Some rusty lines that look like they have holes, not sure if they are return lines or not but definitely not looking good. Fresh install will come in the summer, coming soon!

[2mAn]

Make sure you grind those welds down to make sure there are no pinholes, otherwise it looks great

[Northern]

Looking good here too

[econti]

Looks good honestly, I've never been confident in rust repair so that's impressive