Project track car ’87 325i sedan (re)build

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  • craz azn
    Mod Crazy
    • Jul 2004
    • 745

    #46
    Yikes. Over half a year since my last update, and boy did things go sideways since then! I had grand plans to go nuts on this car... thinking the time was right to do a major change to the bodywork. I figured now was as good a time as ever to look into a more competitive setting as far as racing is concerned by targetting Gridlife GLTC. I've been watching the series now for a few seasons and really wanted to get into it, and this chassis/roll cage I felt was a good platform, even though I knew there were some drawbacks to using an E30, versus a more contemporary BMW chassis. I had a pipedream for awhile to convert the car to a 2 door body, so I purchased a parts car through a local buddy so I could steal the quarters off, and possibly the roof, as I wasn't 100% sure on how the C pillars and inner structure compared between a 2 and 4 door body.





    The plan initially was make the car look like an M3, with the help of some old/spare parts I have kicking around from my M3, and modernize the aero, since that's a somewhat loose rule set within GLTC, and also take the entire driveline from an E90 325i I have kicking around, to do an N52 swap along with the 6spd, ABS, and all that. I can't exactly recall anymore what happened since the last few months have been a blur, but I think it was the wheels that pushed me over the edge; I'd become discouraged that I couldn't easily fit monster wheels on the car, so I ditched the entire plan sometime around January and started focusing on the E90 as a base instead and forgot about the black E30. I ended up getting the car dynoed so I had a baseline, and bought a bunch of crap including some big Apex wheels, MCS dampers, Bimmerworld spherical arms and bearing replacements, 335 brakes, Carbon rear wing, etc...





    In late February, all my plans stopped. A friend sent me a marketplace link to a Porsche 996 for sale, in the exact spec I've been looking for, for years (.1, C2, manual, Yellow, Aerokit). Initially I wasn't even interested because I knew the timing was horrible being that money was tied up between these two ongoing projects, but after thinking about it for a day or so, I figured this opportunity doesn't come along often, and I needed to make this happen for myself, regardless of the circumstances (mind you, this car was on the other side of the country, well over 4500km away!). Within a week, I made arrangements, sent money, booked a flight, and packed a bag along with my license plates and went to go grab it! Probably in my Top 3 most ridiculous things I've ever done, being that I was super unprepared and really pushing my luck buying this car sight-unseen and driving it back. I had to change my travel plans due to weather, and ended up going through the States to get home. Drove from Vancouver BC down to Seattle, then across passing through MT, SD, WI, etc etc... Met some new friends along the way, as well as linking up with an E30 buddy in WI, but for the most part the trip went well, and I got back to Toronto with an intact car! Very happy with my decision, and it makes a great garage buddy alongside the M3.





    So back to the black E30! I knew the car needed to be fixed, whether I was keeping it around long term, or looked towards putting it for sale, so something had to be done. I decided to just keep it as is, 4 door, and do a quick fix to make it complete, just as how my plans were last fall before my dreams of going competitive racing with it. In April, I finally had the chance to bring it to my friend's shop where he'd let me take a stab at trying to pull it, with his guidance along the way. Unfortunately after my first attempt at pulling it, taking it home and working on it for two days straight, I came to the conclusion it wasn't pulled enough because nothing would line up. I was super frustrated and let the car sit in the corner for a few weeks, while I waited for my friend to have the shop/frame machine free again so I could bring it by a second time.







    Second visit to the bodyshop (now in mid-May), I also brought along a spare trunk lid that was straight, and that helped as a reference to make sure everything was looking better. Also, I obtained a quarter panel cut from a parts car that another local E30 owner had, who generously donated it to me for free to help out with the repair. Another day spent on it in the shop ended up working out well. Things are only tacked in place at the moment as a temporary measure, so I can finesse and move things around to try and perfect the fitment.







    Hopefully more frequent updates to follow!​

    Rippin' Proper | Youtube | Vimeo |

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    • CubbyChowder
      E30 Fanatic
      • Mar 2012
      • 1488

      #47
      Just reread through this whole build, what a rollercoaster! Between the mad dash engine rebuild and now the rear damage. Really liking all the self-made solutions you've come up with and how you jump right into action when shit goes awry and needs fixing. Plus, you're making me want to get back out on track! Do you think you'll keep the E30 or shift your focus to the E90 project?


      --Roundie Revival 2.0 - 1973 BMW 2002 Build Thread--
      --Golden Boy E30 Build Thread-- (sold)

      Comment

      • craz azn
        Mod Crazy
        • Jul 2004
        • 745

        #48
        Originally posted by CubbyChowder
        Just reread through this whole build, what a rollercoaster! Between the mad dash engine rebuild and now the rear damage. Really liking all the self-made solutions you've come up with and how you jump right into action when shit goes awry and needs fixing. Plus, you're making me want to get back out on track! Do you think you'll keep the E30 or shift your focus to the E90 project?
        Thanks dude! Heck yeah, the track is where it's at! I daresay it's one of the best places to enjoy these cars. Biased slightly, being that almost all of my track experience in the beginning was based around E30s. I'm proud to say that, because had I learned in a more modern/faster car, I don't think my driving skill would be where it is today.

        Great question on what will stick around, and what will go. To be honest, I haven't really given it serious thought just yet. The E90 is practically worth nothing, as they are a dime a dozen these days. Although, I have a hard time parting with it, as it was my daily for years, and it was good to me. Just shy of 100k kms of within my ownership!

        ------------------------

        This past week, I ended up massaging the new replacement panel into a better position, as the uneven bodyline was bothering me. I ended up cutting almost all the tack welds off that my buddy had helped with at the bodyshop, and I ended up pushing it all downwards, and slightly inwards towards the center of the car. I also had to tack, and eventually connect the metal piece below the driver side tail light, as we'd cut it off to get everything to line up. I also welded in some filler pieces in the license plate area, remnants of the previous owner's projected plan to put wing uprights through the rear tail panel! After a lot of fettling about, the tail lights now line up almost 100%, trunk closes perfect, and the bodyline down the left side of the car is better... not perfect, but being how I've chosen to repair this, its as good as its gonna get! I'm happy with that! Next up, time to start on the rear bumper/lower skirt, and repairing the rear wing where all the mounts ripped out.













        Rippin' Proper | Youtube | Vimeo |

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        • craz azn
          Mod Crazy
          • Jul 2004
          • 745

          #49
          Finally with all the welding done.. just need to grind down the big stuff, and leave the rest for the bodyshop to skim over with a thin coat of filler. One mistake I made: using the car as a workbench! I had put the taillights on the roof out of the way while test fitting everything. But, when hammering the body, one of the taillights wiggled its way off the roof and smashed down onto the floor. I tried to scrounge up as many of the broken pieces as I could, and glued them back into place, and filled the remaining gaps with epoxy that I had, which unfortunately I found out after was not clear. Ah well... its a racecar, and it looks good enough from 5ft away. Still bummed out that I messed up yet another nice taillight, as these are getting hard to come by locally.





          Last weeks progress was the bumper, and getting all that to fit. I found out that my old bumper/bumper shocks were bent, maybe even from its previous life before me, because when I installed the new bumper rebar/shocks from my 2dr parts car, everything lined up perfectly first try! Pretty happy with that. I started to cut the bumper ends to fit, as we know the facelift bumper is too long for a prefacelift body. Although, I did change up my mounting solution for the sides... instead of using the dzus fastener from my first attempt, I just tack welded an L shape bracket onto the body, and the upper tab of the bumper slider just rides along that. The way the bumper is held down and in place will be through the sides of the lower skirt (once attached to the bumper), as those have self tapping screws into the flange of the fender arch, as per how I had it originally. Just trying to simplify the install!



          This past weekend, I finally got around to that dreaded lower skirt. I'm not particularly a fan of dealing with messy fiberglass, and I knew there were a lot of cracks, stressed areas, etc that needed to be dealt with. I ended up grinding off some trouble areas on the inside, and getting my patch pieces of mat pre-cut so I could have everything ready to go.





          The weather this weekend was hot and humid, so I put in a few drops less of hardener into my resin, hoping for a bit more working time... somehow that was a miscalculation because it took hours for stuff to dry. Oops! Had to bust out the trusty heat gun to speed up that process! After that, a bit of cutting, trimming, and a few rivets installed for temporary placement, the skirt is finally back on the car. I have to go back and fix all the outer cracks and messed up spots with filler, but at least it is placed onto the car, and everything seems to line up, look even side to side, etc. Sweet!





          Next update will be the wing, which a small corner got shaved off from hitting the concrete wall, and fixing all the inner parts with the screws ripped out. After then, my work should be done, and it will be ready to head back to the bodyshop for the final time for paint! Super excited!

          Rippin' Proper | Youtube | Vimeo |

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          • craz azn
            Mod Crazy
            • Jul 2004
            • 745

            #50
            So I got the wing finished up... that ended up being the easiest fix so far. I patched the underside as well with the same epoxy, let it set overnight, and redrilled the mounting hole at the bottom. What sucked was placing the wing on the new trunk. I didn't notice at the time, but the 'new' black used trunk from the parts car is not an original iS trunk with the holes for the lip spoiler... turns out it was cut in by somebody else, so naturally all the holes are in the wrong spot or wonky. I had to dremel out half of them, and use monster washers inside to place the wing onto the trunk (The bottom piece of the M Tech II rear wing uses the same mounting hole locations as an iS lip)



            I ended up playing with the trunk gaps and alignment. I had to finish modifying the passenger trunk hinge that I started on a few months ago, to get the trunk height correct... and now once the wing was bolted on, it made it more obvious that the side to side alignment needed some perfecting, so I just bandaided that by adjusting the trunk latch over to one side, so when it latches shut it pulls the trunk over a touch.







            Sweet! While I had the fiberglass filler out to repair the rear valance/skirt, I figured I should double check the side skirts, and just give everything a once over... I fell into another trap of trying to make things better... namely, the passenger side skirt, as it had a bit of a gap on the top edge against the rocker, and it was bugging me. So I ended up filling it, and sanding that flat. Messy, but necessary.



            Once that was done, I started to glass anything on the backside that looked like it was thin, cracking, or questionable.



            Last thing on the fiberglass list was to cut the lines into the M Tech I items that had gotten damaged from hitting the wall. And angle grinder, cutoff wheel, and a small file ended up making it happen. Very happy with how that turned out, at the expense of the dust and mess it made. Sorry shop!





            I guess now I was done, everything all fitted and ready to go for the paint shop. Or so I thought... One thing that really kept bugging me was the sunroof delete plug. It basically had cracks all the way around the perimeter in the roof, and I knew that if we just painted over it all, it would just reappear immediately, and that would drive me nuts (not to mention it literally leaked water inside the car). Soooo... I dug into it. And boy, did I open one heck of a can of worms!





            Uh oh





            Basically, what's happening here is it looks like the panel is some sort of corrugated plastic or something... held in with a few self tappers (red arrow), and entirely filled over with different types of bondo... what a freakin' mess! Thanks previous bodyshop :(

            Aaaaand... success! It's out! Damn, it was heavy! I bet between that, and the bondo in the roof, it probably weighed almost as much as a stock sunrof panel. Not kidding. Gross!



            Luckily, that parts car came in handy again! It had a sunroof panel that wasn't terribly rusty, but still imperfect enough that I didn't feel bad to cut it up. I gave it a go to try and cut the inner framework out, to help get the weight down... then this way, I'd have a roof that was actually the correct curvature, with as little amount of bondo as possible. In the grand scheme of things, I wouldn't mind if the net cost was even a few pounds more, as long as it looked better than it was, and sealed well.







            Time to get this thing installed permanently!

            Rippin' Proper | Youtube | Vimeo |

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            • craz azn
              Mod Crazy
              • Jul 2004
              • 745

              #51
              Left off with the sunroof. Got that levelled out and tacked into place.



              Lookin' good! Pretty excited with that. I swapped some junk wheels onto the car that wouldn't mind an extra bit of overspray, along with a stock driver seat that I didn't care much for to help save my race seat from getting wrecked with the dust and whatnot while in the shop. Pfeewwwww... finally ready to go for paint! Although my daily X5 seemed to have other ideas... On my trip to the shop with the trailer in tow, it started to hiccup and randomly shut down. Another failing injector! Ugh. I ended up turning around part-way, and had to push the E30's delivery date to the paint shop back by another week while I ordered parts, and installed them into the X5.

              Once the E30 made it to the shop a few weeks later, progress could start pretty quickly and even I was allowed to stick around and help with some basic and remedial tasks.

              Trying to flatten out the bondo in the roof from the previous install



              Lots of sanding and filling to go!







              Some primer going down









              Hopefully some nice shiny paint in the next post!

              Rippin' Proper | Youtube | Vimeo |

              Comment

              • Northern
                R3V Elite
                • Nov 2010
                • 5050

                #52
                looking great. I need to get on my sunroof delete before the thing falls into the car...
                Originally posted by priapism
                My girl don't know shit, but she bakes a mean cupcake.
                Originally posted by shameson
                Usually it's best not to know how much money you have into your e30

                Comment

                • 2mAn
                  Señior Mod
                  • Aug 2010
                  • 20124

                  #53
                  Great seeing updates on this! Nice pick up on the SY .1 ... is the Aerokit factory? Theres a handful of R3V owners in the 996 group... we know a good car and a good value I guess.
                  Simon
                  Current Cars:
                  -1966 Lotus Elan
                  -1986 German Car
                  -2006 Volkswagen Jetta TDI

                  Make R3V Great Again -2020

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                  • Gaarath378
                    Member
                    • May 2024
                    • 96

                    #54
                    Wow - what a clusterfuck with the sunroof; im sure the slick top will look good! I thought that corrugated plastic crap was cardboard for a second, youll be glad you ended up putting time into that down the road.
                    Bronzits Biggest Fan

                    Comment

                    • craz azn
                      Mod Crazy
                      • Jul 2004
                      • 745

                      #55
                      Originally posted by Northern
                      looking great. I need to get on my sunroof delete before the thing falls into the car...
                      Lol! Get it!

                      Originally posted by 2mAn
                      Great seeing updates on this! Nice pick up on the SY .1 ... is the Aerokit factory? Theres a handful of R3V owners in the 996 group... we know a good car and a good value I guess.
                      Thanks man! Yes sir, factory kit! Agreed... Love it! Maybe I'm biased because I'm still in the honeymoon phase, but I really appreciate the design, both interior and exterior. It's almost ahead of its time. I drove a buddy's 997 a few weeks ago, and was appalled by the interior/ergonomic design. Maybe slightly better driveline, but nowhere near enough better to make me want one.

                      Originally posted by Gaarath378
                      Wow - what a clusterfuck with the sunroof; im sure the slick top will look good! I thought that corrugated plastic crap was cardboard for a second, youll be glad you ended up putting time into that down the road.
                      Thanks man! Yep, you bet, it was a good decision to get that roof fixed up. Will show more in my next post :)

                      Rippin' Proper | Youtube | Vimeo |

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                      • craz azn
                        Mod Crazy
                        • Jul 2004
                        • 745

                        #56
                        Just before we hit the booth... Check out that roof! Woooo!



                        Taped up!



                        Part circumstance, part impatience... I asked my buddy to paint everything in one go, as he was leaving for vacation the following day. In doing so, all the parts had to be crammed into the booth, making it super tight for him to spray. This ended up with some parts not having perfect coverage (mostly the side skirts) as well as some dust in the paintwork. That said, almost all of it will buff out, as this base/clear setup is pretty robust. I think it goes without saying, this is the best this car will ever look. Lol.





                        Hell yeah!





                        Starting to get this thing put back together. First thing was a face... All the grills and headlights back in. Oh, and ditching those awful roller wheels, and back onto the track wheels. I also bought a new (used) set of spacers... Now running a 15mm up front, and an 8mm at the rear.



                        Onto a job I haven't done in well over ten years: I forgot how horrid E30 window lockstrips are... These things killed my fingers! And, to add insult to injury, my saved black front lockstrip from my parts stash had shrunk! Good thing its a racecar, otherwise this would bug me to no end. I'll just cut a small piece out of an old lockstrip to make up the difference.





                        Got the wing back on, lights installed... had a bit of an episode trying to figure out why my signals and stuff weren't working, but it turns out I'd forgotten a ground. D'oh!





                        Rippin' Proper | Youtube | Vimeo |

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                        • CubbyChowder
                          E30 Fanatic
                          • Mar 2012
                          • 1488

                          #57
                          Hell yeah! Looks awesome


                          --Roundie Revival 2.0 - 1973 BMW 2002 Build Thread--
                          --Golden Boy E30 Build Thread-- (sold)

                          Comment

                          • Northern
                            R3V Elite
                            • Nov 2010
                            • 5050

                            #58
                            holy shit that looks good
                            Originally posted by priapism
                            My girl don't know shit, but she bakes a mean cupcake.
                            Originally posted by shameson
                            Usually it's best not to know how much money you have into your e30

                            Comment

                            • craz azn
                              Mod Crazy
                              • Jul 2004
                              • 745

                              #59
                              Thanks dudes! It's coming along!

                              ----------------------------

                              I bought a stapler, and a plastic welding iron because I knew I had to deal with the rear bumper trim, since the rear bumper is now shortened to fit an early model body. I had to also change the angle of the leading edge of bumper trim, since I've now added that replica M Tech 1 rear skirt under it.

                              This thing is the bomb! The kit comes with different styles of staples, but I mostly used the squiggle shaped ones, since they seemed the most apt to strengthen any cuts/joints. I have to thank my buddy at the bodyshop for introducing me to this tool. Its so satisfying.



                              And the plastic iron. Good for flattening out after the staple, as well as filling gaps.



                              In this picture, the marker line to the edge of where I cut is how much needs to be removed from the trim. Almost a good 10mm or so.



                              Joint in the middle





                              And the leading edge of trim. Slightly tougher, but I got it figured out!





                              Once bondoed, sanded, fitted, sanded some more, re-painted due to screw ups, wrinkling, etc lol... this is pretty much how it ended up! Sick! Worth the effort.



                              Unfortunately, not all is perfect. I had to paint the door trim with satin, as it was gloss via previous owner/bodyshop. I wrapped the side of the car with plastic... but clearly I need to tap into my inner Dexter a little bit better... I should have covered the whole car, because it was covered in overspray after, both on the sides, and the middle of the roof... FUUUU! After calming down about it, a fresh microfiber with a light dousing of fuel just took the overspray of without worry.





                              And more fuck ups... I'd bought some sealer on recommendation from our local Napa to seal the sunroof gap. I probably should have followed my gut feeling to just use generic black sealer from the hardware store... but silly me wanted something automotive grade from the parts store. In hindsight, bad idea. I bought all this fancy 3M tape to try and create a nice cut line so it would look sharp... but it just didn't work out that smooth. First attempt: I put down a bead of sealer all around the perimeter... by the time I got to the start point, it was already skinning over, making it really tough to flatten out and maneuver with my finger. I don't have any pictures of this process because I was a bit flustered at the time, not wanting to touch the car (have I mentioned yet that fresh black paint SUCKS to work with) and I had to clean off any excess sealer before it completely dried asap. Once it dried... it was all low, wavy, and just generally not pleasing looking. I let it sit for a couple of days to cure fully, and went back to attack it for a second attempt, hoping that a thinner coat of sealer, plus more added masking tape to give myself some extra room to liberally apply sealer and not worry about it getting onto the paint. Ugh. Equally just as bad of a time...





                              As you can see from the above picture, when I'd pull the tape off, the excess wouldn't actually go with the tape, but instead fold over back onto the sealer itself. At this point, I had no other option as it was drying really quickly... I tried to spray a bit of fuel on one of my fingers and try to flatten it out, at the expense of it getting all over the paint.







                              It took me awhile to clean up the mess with fuel, cotton rags, and lastly polishing up what I could with some spray wax to hide some of the scratches from touching it (Fresh black paint UGHHHHHHHHH, nightmare!) But I'm leaving it at that. Its smoother than the first attempt, and its fully sealed around the perimeter. Its certainly quite an improvement to what I started with.



                              I'm aiming to sign up for a track event in a week and a half from now, so I've got my work cut out for me to finish assembly, finish cleaning up the remnants of the bodyshop dust and mess, give the car a good checkover, new fluids, etc... This weekend will be busy! Hopefully more updates next week.

                              Rippin' Proper | Youtube | Vimeo |

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                              • craz azn
                                Mod Crazy
                                • Jul 2004
                                • 745

                                #60
                                One small side project I dove into was the wipers. I always wanted to find out what made single wiper conversions a thing on E30s, so one evening I set out on removing the linkage from the car. Luckily, a relatively easy job without the original heater box/fan mechanism in the way.

                                Ha, check this out!! Made here at home!! I never knew! Kinda cool!



                                So after playing around with this a bit, turns out this linkage needs to be shortened.



                                My first attempt, it wasn't short enough. It definitely changed, but it wasn't sweeping much more than the original travel.





                                I cut it, shortened it another couple mm, and tried again. Nice! I would manage to get about 160-170 degrees of travel. Probably about as good as it gets with this method. Unfortunately, I think I shortened that lever too much, and there was a faint metallic clink noise happening on each rotation of the wipers while in motion. I took a closer look and realized that now the movement had changed so much, it was contacting the main linkage bar, the one that transfers to the motion to both wiper arms at the same time. Crap. Out comes the grinder once more, and I kept grinding until I got some clearance. A few quick dabs of weld with a thin piece of metal were used to gusset back the side that was cut off, and good to go!




                                Last thing was to heat up the wiper arm itself, and give it a bend so it would land the wiper straight on the driver side... much like a RHD car would I guess.



                                I plan to just direct wire the motor with a switch on the dash just to keep it simple, so I won't need to worry about different speeds, where the wiper parks, etc.

                                Other tasks on the list were to get the seat fitted. I have replaced the Recaro with a Racetech I found on our local kijiji from a Porsche PCA racer and got that mounted in with another set of side mounts. Big seat! Almost bigger than the Recaro XL that was previously in here. ​One downside was the Racetech had a massive lower cushion, so I had to remove that to sit lower... and create my own smaller under-knee bolster cushion just to help support a bit. 25 dollars of foam and black cloth, along with some old upholstery spray glue I had kicking around, made for a quick custom-made solution. I thought it turned out pretty good, but since I snapped this picture, I've torn off the cloth again, sanded the foam some more and reglued the fabric back on, in an effort to try and smooth out the cushion so it didn't look so wavy and wrinkly.




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