A Tale of 2 Sedans M42/S52

[eternal24k]

While I wait for the new body shop, that is about 6 weeks behind their original estimate and no longer returning messages, I am trying to stay positive and make progress.

One thing I did promise my wife was that I would get some of the boxes filling our office space. Many of these are small parts from the original body shop completely disassembling EVERYTHING. But a couple large boxes were my brand new OEM carpet I got from ECS a year or two ago, and the new Recaro seats. So I finally tackled the carpet and heated seat wiring...

Old carpet wasn't too bad, honestly, seeing how good the toad looks after a few years of ColorBond, I am sure that would have looked great.


I took the time to use up some sound deadening material. Less boxes in garage and maybe more quiet ride, win-win


One thing about the seat wiring, the seats came with an aftermarket heater installed, with a round, cheap feeling switch. I really wanted to keep the square switches, they are bigger, more period correct looking. Surprisingly, the behavior of these switches was not super intuitive, with some wires switching polarity based on switch position. But after confirming that both switches behaved identically, I re-wired the switches. My wiring may look like overkill, often using barrel crimps with solder, but after seeing the POs wiring, I have spent a lot of time to re-do much and ensure very good connections (things like the wireless door unlocker had poor connections that led to intermittent operation).




For power, luckily the auxiliary fuse box was un-used, and since the switched (green) wire is rated for 15amp, and each seat for 7.5, I spliced off that and put two 7.5 amp fuses in the box for a completely OEM looking setup under the hood (I hate in-line fuses everywhere).

I sheathed the two wires in Raychem with an o-ring for a step, this gets pushed into the boot to hold them in



Brand new carpet!

First impressions:
THE GOOD

• Very thick, high quality foam, maybe it's just new, but it seems more plush and conforming
• great look

THE NOT SO GOOD

• A couple small imperfections in the nap, almost looks like burns, luckily behind pedals and the seat.
• there's plastic on the dead pedal or foot area for the driver, I liked this on the high wear on the original, but I have all weather mats, so not a huge deal
• some minor trimming, there's no cutout for things like the kick panel clip like the original

I still have some minor fitting to do, I may look for weights and strong magnets to help conform the carpet. After that, I have a new OEM door seal for the driver's door, the other 3 will likely get the Turkish seals since they have proven to work well for me

[eternal24k]

Edit *duplicate*

[eternal24k]

While I wait for the paint shop to paint my doors and sunroof and other small bits (pray for me) I went through our winter wagon and completely refreshed the suspension on the E91. New shocks, springs, small bits, wheel bearings to complement it's recent 200k cooling system overhaul (with original water pump!)

I even sourced like new knuckles so i didn't have to struggle with my crusty units. The springs were a masssive PITA, i couldnt get the drop hat on with my compressor, local shop couldnt either, and the third spot said they barely could. But she handles better than ever now...

[eternal24k]

Love the build, what is your solution for the inside of the sunroof delete?

thanks! In terms of aesthetics? I don't look up

The carbon fiber look doesnt bother me and the lack of headliner is a bigger eye sore, but the S52 swapped car and E91 have been my priority lately, so I just drive and enjoy "the toad"

[Graham325]

Love the build, what is your solution for the inside of the sunroof delete?

[eternal24k]

And then there is the wet sanding, there were some minor fish eyes and other imperfections that needed to get worked out...

Started on the trunk side of things, 2k followed by 3k wet sanding, then Griots Fast Correcting Cream, then Menzerna 2500 medium cut, and finally 3500 polish. I was very nervous as I've never wet sanded or cut/polished a car before, there was awhile during cutting that I thought i was never going to get the sanding marks out. But after getting more aggressive pads, my fear faded away. The rear looks amazing, hardest part is all of the fuzz my microfiber towels leave behind, but this color is as hard to photograph as anything for someone of my skill level.









putting the brand new roundel on the back felt really good today. Now i need to tackle the front...

[eternal24k]

As always, things have been slow, but making progress...
First up, I installed the HIK skid plate and matched the weld area with Wurth texture prior, don't mind the antiseize thumb prints, it's actually clean ;)




And while my wife has been out, I have been cleaning up the hood for new foam (fun fact, a twin sheet makes a perfect hood protector)



And i started prepping tail lights, a bit unnerving to do on a brand new set, but I had the old pair to practice on, and to be honest, they look just as good....

[eternal24k]

Some of the small plastics are available still new. Buy while you can.

AWDBOB May have all the factory heated seat wiring while the carpet is out. There are heated seat “carbon” mats kits you can get from Jegs or Summit.

I have a perfect head unit and nice smaller sub in my car that work quite well, better yet, like factory. It’s somewhere in build threadz.

Glad too see you found a painter, that’s a tough one.

right now I am trying to sort through parts before I buy more. I have things like all new bumper trim, but I also have bags of clips and things I bought two years ago for this job, trying to get a handle on it as I have recently found myself buying things I forgot I already had....

The seats have the carbon heat elements added, I want to look to see if my car has the box under the dash for adding the factory wiring, adapting those to plug into my seats would be ideal, but what I've been reading it seems like the jury is out whether or not cars without heated seats have the setup to add them.

I have a Clarion FZ102E, I think they are perfect for E30-E36, but my speaker wiring is all large plugs (not sure the proper name) into the back of the head unit, probably ideal for an audiophile, but makes other units much harder, I am not sure how i would tackle that. I'll take a look at your box for inspiration :D


Your build thread is amazing! I will be making a pot of coffee and combing through that today...

[moatilliatta]

Some of the small plastics are available still new. Buy while you can.

AWDBOB May have all the factory heated seat wiring while the carpet is out. There are heated seat “carbon” mats kits you can get from Jegs or Summit.

I have a perfect head unit and nice smaller sub in my car that work quite well, better yet, like factory. It’s somewhere in build threadz.

Glad too see you found a painter, that’s a tough one.

[eternal24k]

The biggest thing I struggle with is the amount of things I have to put together, and worrying about the proper, or best order to do them. But for my own planning, below is a list of things I know I have left (in no real order):

BODY

• install valance
• install fenders
• Install hood
• Bumpers, trim, and roundels
• reassemble doors and sunroof and wiring
• figure out the fender liners
• wet sand and polish paint
• replace door seals
• Install HIK skid plate

INTERIOR

• Install new carpet
• figure out how to wire heated seats for new recaros
• finish oil pressure gauge
• dig into sound system (i need a sub, hate the head unit)
• install billet handles

It doesn't look so bad in a short list like this

[eternal24k]

And for the S52 swappie....
I was finally able to find a painter to finish the doors, sunroof, spoiler, and trim. Bonus is that he works with the same water based paint that I provided, so I am optimistic the parts will match and hopefully will have everything back in a couple weeks. But I still have many boxes and bins, and bags of small parts, some without labels that I will need to figure out.

I started with the trunk, I was able to mount the trunk, figure out the lock mechanism and reinstall all of that, and while I was in there, clean up some wiring for the double trunk lights.

The other things I am doing is spraying all interior panels and such with a cosmoline like rust preventative from CRC (being from the north east, I am paranoid about rust, even if this will never see snow). it goes on wet, and dries in a mat wax that is not messy or sticky. I started with a small test bit on the bumper



I am so happy with how this stuff comes out, I am painting the inside of the new OEM valance and coating those along with the new fenders



and of course, SEM Ultra on small plastics



and I scored this guy (part of me is motivated to add more weight so the MT2 springs don't launch the trunk open so fast

[eternal24k]

Worked on the M42 car, or "Tilly the Toad" as my wife calls it.
Finally dug into the AC. When i swapped the motor I put a new dryer and oil in the system, so I pulled a vacuum, things looked good, and filled it up with Redtek 12A.


It was blowing cool as i filled it, but I am not sure if Redtek's info is correct in terms of pressure, or I have another issue. But at the end of it, the compressor would kick on for a split second, and stop. I do not know if the system is over pressure or it's got something wrong. I plan on bleeding off some pressure and trying again.

shortly after, I sprayed the engine bay down to get rid of all the pollen, and then it wouldn't start (cranking no start)

Long story short, I spent days drying it out, I check every plug, sprayed every connection with electronics cleaner, pulled the plugs, tested many things. Then I noticed the cam positions sensor was damaged, had a fray in the wire. So I pulled it out, soldered a connector, but still nothing. I then went through my M42 parts, tried another Cam sensor I had, but it wouldn't start. Swapped a DMW I had, and while looking at the DME, noticed it was opened, so I peaked inside and found a Dinan chip (sweet)

but still nothing...

Reading up, I learned that the car starts via wasted spark, until the cam sensor picks up a signal, but can run wasted spark without the sensor. So I unplugged the cam sensor, and it fired right up! Been driving it for a few hundred miles fine while I wait for a new sensor. I had previously tried Facet, didn't work, purchased an NTK that is supposed to be for a '91, but the plug was for an E36 (despite the photos showing a 3 tab, not 4 tab plug). So I am still working to find a solution... Either way, glad to have it running again, hopefully can square away the AC soon...

[eternal24k]

The cars are looking great! With the touring, having driven my 320i for a few years prior to swapping it, you can wake up the 2.0L with a manual swap and 4.10 diff ratio. This will make it much more entertaining to drive.

For swapping, given the Alpina tribute themes going on I’d lean to one of the period correct engines - a built stroked M20 or an M30 swap

I’d lean to the M30 (of course) but I’m sure the result will be great whichever way you go.

Yeah, I think a manual swap will hold me over for awhile. Due to the tribute, keeping it Bavarian makes the most sense.... But damn do I want a Kswap. Maybe I will pull the S52 and throw it in there

In other news, I now have possession of the Brewster green car, MANY boxes/bins of parts, I will have to learn even more as i put it back together. Shame being that the doors and spoiler and small trim need to be painted, praying I can find someone to match to the body well. I was given the remaining paint, but it's water based and those I have spoken with are hesitant about that.

I'll be wet sanding, sorting through boxes, cleaning the dust and tackling this over the next couple months.... For those who have reassembled a car, any tips or suggestions would be appreciated. Right now i plan on getting some cosmoline/wax undercoating for the interiors, greasing all moving parts in doors, and replacing seals. But any specifics or other suggestions will be gladly received.



I'm still obsessed with this color. Can't wait to complete the dream



SO FILTHY... but dash still crack free :)

[lukeADE335i]

But on the positive side, was able to pick up the wagon and road trip it home



The Plan:
right now, just go over all the wiring, try to get the wiring done, eventually replace all bushings with OEM, going to keep this as OEM+ as possible, no poly on this build. Very torn on what to do with drivetrain, would love a K swap, but that doesn't feel right for the Alpina tribute. I do have a G240 and driveshaft, I may just manual swap it for now and continue to mull over the motor situation...

The cars are looking great! With the touring, having driven my 320i for a few years prior to swapping it, you can wake up the 2.0L with a manual swap and 4.10 diff ratio. This will make it much more entertaining to drive.

For swapping, given the Alpina tribute themes going on I’d lean to one of the period correct engines - a built stroked M20 or an M30 swap

I’d lean to the M30 (of course) but I’m sure the result will be great whichever way you go.

[eternal24k]

Great thread. And the touring --- oh hell yes. Love the way it looks as is - silver is one of my faves on them.

I get the want for more go. I have dreams of k swapping my touring (m42/5speed) but not until I really want to go down that rabbit hole and have more garage space.

Thanks! I agree, the silver just works so well... And I feel you, the K swap will take a lot more time than the S52 swap, and I do not have the space for it. Especially with the S52 car being half painted.... Long story short, I will be picking up the car and MANY bins of parts and taking them home. With my garage so tight, i will likely be filling up the office/project room in the house with parts. The paint looks great, but the business closed and internal drama means I have to find a painter to finish the doors, trim and spoiler. On the positive side, it means i can take my time reassembling, undercoating bits and doing everything exactly as i wanted it, but needless to say, I wont be tackling the touring in the near future



Tomorrow i head out with a Uhaul van and my father to organize and pack up all the parts and take them home. With no doors or sunroof, my garage will be dominated for awhile.