Project George: Less ('87)is More

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  • Shad0w
    Noobie
    • Mar 2014
    • 15

    #1

    Project George: Less ('87)is More

    Background
    So this isnt my first rodeo, I purchased my first E30 in the Fall of 2014. I made it into a street machine with an M30 swap with Condor bushings everywhere sitting on Ground Control coilovers. Ive daily driven it for the past 2 and half years with the odd issue popping up here and there. Thread found here sadly it was hurt by the Photobucket plague: https://www.r3vlimited.com/board/sho...d.php?t=347952





    As many of us know E30s can become an obsession, and that just naturally infects those around you in my case my family, around this time (Spring 2015) my younger brother was due to get his first car and thankfully I manage to steer him in the right direction to getting an 1986 325e coupe.

    So naturally we M30 swapped that one as well, the low end torque of the M30 makes it arguably the best engine for enjoyable daily driving. Threw some BC Racing coilovers on it and he has enjoyed daily driving it for the past year and a half without issue.





    During all this time our Dad had been a helping hand building these cars and the inspiration to dive head first into any problem encountered. Our combined experience previous to finding the E30 world was limited to the odd repair here and there, brake jobs and oil changes.

    While helping with these two E30s he had gotten the itch to find one for himself, over many months of watching craigslist for the right candidate he found this Delphin 1987 325is in the local neighbourhood with a classic Walmart for sale sign in the window.

    Its what can be called the dream E30:
    303,000KM on the clock (189,000 miles)
    5-Speed
    3.73 LSD
    Delphin metallic in good shape
    Window trim not oxidized
    Houndstooth Sports Interior
    13 Button OBC
    Ski pass through
    Weaves
    Huusco arm rest



    It's a 2 owner 325is that had been owned by an elderly lady for the past 17 years, it's been a British Columbia car it's whole life. Started life in the interior of BC and spent a few years in Northern BC, Northern BC has harsh winter and it was driving thru winter (remember this for later), then moved to Vancouver Island in 2001. It has been meticulously maintained throughout its life, whatever the mechanics told the PO it needed she got serviced, the dream service records you want to see when purchasing a car.





    So my father purchased the car and it sat for a few months while he was busy with other things, it needed a solid going through to make it a good driver and this all takes time. Well as things change my Dad determined he wasn't up to giving this car a second life, knowing damn well that I was jealous of his find he offer it to me at the price he paid. I simply couldn't say no even if I wasn't looking for a new one.

    As I went all out in my previous E30 I built what I thought at the time as the ultimate street car, solid bushings loud and stiff. While I do love the Luxor E30 after 2 and half years it was clear that the ultimate daily driver could be done differently. With this 87is the plan is to more inspired by the OEM+ mentality.

    The Plan
    Done:
    M20 engine refresh (seals, gaskets)
    Fresh suspension bushings all around
    Rebuild brakes
    New Brake Hardlines
    Tackle the rust
    Fix the interior seat tear

    To be done:
    Steal the Ground Control coilovers from the Luxor
    Engine swap down the road


    We are currently about 4 months head on this project so I will do my best to get this caught up

    Cheers, Ian
    Last edited by Shad0w; 10-28-2017, 05:18 PM.
  • Stvstr
    Member
    • Dec 2013
    • 82

    #2
    Very nice, but I am biased since I have a Delphin '88 325is that looks almost identical and an '84 318i currently getting an m30. And I live in Comox so it's nice to see a build in my general neighbourhood.

    Comment

    • JRYE30
      E30 Addict
      • Sep 2011
      • 465

      #3
      Awesome! Love that the whole family got hooked haha. I’m in Chilliwack just an hour(ish) east. Also with a Delphin ��

      1987 325 | @e30_hunter |

      Comment

      • Shad0w
        Noobie
        • Mar 2014
        • 15

        #4
        Engine Refresh
        One of the biggest bonuses with this car is that in 2012 the PO had the cylinder head completely rebuilt with new rocker arms, new valve guides, head hot tanked and resurfaced. The engine however leaked like a sieve from no where in particular and appeared to have been leaking for the past few years.

        So to rejuvenate the power plant we made the call to pull the engine, pull it apart, inspect everything and completely reseal it. Prior to pulling the engine we compression tested it dry and got all 6 cylinders reading around 155psi +/- 4psi (need to find my data from this). This was encouraging that we had a healthy starting point with this M20B25

        On July 21st, 2017 my brother and I put aside a complete Saturday to pull the engine and transmission





        And just like that we add an empty engine bay



        Threw the dirty engine on the stand



        After some quality time with a couple nylon brushed and Super Clean (I cant recommend this stuff enough for cleaning oily parts) we had something that was acceptable to work on



        Fast forward a little further down disassembly and we got the cylinder head off



        Cylinder head looking as fresh as advertised, there is now only 15,000kms (9300 Miles) on the head





        Typical Carbon build up on the piston tops after 300,000kms, this is piston #1 and the rest of the piston tops are all very similar, not raising any further worries. This carbon was easily removed using camp fire fuel and a plastic scrapper. The cross hatching is also still in surprisingly good condition considering the mileage.





        At this time I also got the opportunity to remove the oil pan and inspect the main and connecting rod bearings, I didn't manage to get photos of this process but I was happy with the condition of the bearings and decided to move forward with the current bearings. These BMW bearings are surprisingly resilient when the lubrication system is properly maintain.

        This point in time it was time to make a parts list for the entire car and submit an order to Blunttech. This order took a very surprising 5 and a half weeks to arrive at my house, stalling any further engine progress at this point. A real pain in the ass but it was out of my hands so time to work on other parts of the car
        Last edited by Shad0w; 10-28-2017, 05:19 PM.

        Comment

        • Shad0w
          Noobie
          • Mar 2014
          • 15

          #5
          Brakes
          While we waited on a parts order my Dad took the chance to clean up the original brake callipers


          After spending some time with a wire wheel


          Cleaned up the pistons and cylinders, threw some VHT black calliper paint and all new seals then we have brand new brakes


          Rust

          The car as a whole seemed very rust free, "seemed" being the operative word, nothing visible from the outside apart from the driver's side door skin needing replacement. If you recall this car spent a few years up northern being driven through winter and we are about to find proof of that.

          While pulling the engine we removed both front fenders to store them safely away from the project, by doing this it shed some light on the first big "oh shit" moment. This is the driver's side front foot well


          This portion of the build was easily the most intimidating part, within the my family we had zero experience welding. We had never done rust repair before, the thought of just cutting into this car with zip discs and sawzalls hurt, having no experience graphing in fresh metal I knew this task was going to take a long time.


          Upon deep inspection we found that the passenger's side footwell looked the same, a rear muffler hanger had rusted off and the passenger's rear wheel well was a real mess. I still kick myself to this day for not being smart enough to take photos as I work.

          We started at the driver's side footwell with the hole you see above. Cut some donor metal out of a local parts car.


          After much longer than I'd like to admit I got the piece to fit nicely with tight enough gaps to butt weld.
          For anyone new to welding, I don't recommend learning on sheet metal. There is not a lot of room for error when it comes to heat management. However if you are like me and sheet metal is your starting point, making sure there is minimal gaps between the pieces is your best bet for success




          Little bit of grinding and some undercoating and we get something like this ready for another 30 years


          Similar procedure for the passenger's footwell. After a hot date with a zip disc and we get something like this


          Some more donor metal


          And we snap our fingers and poof


          Anyhow we'll leave it here for today, more rust to find and destroy soon.
          Cheers, Ian

          Comment

          • MCreally?
            Member
            • Apr 2017
            • 52

            #6
            you did a lot better than i did welding that section in, I HATE that spot. I found that having a welder with infant adjustment works best for sheetmetal. sometimes the gauge is in-between settings on your typical notch style power selectors. I will be following this one. It is very similar to what I have done to date. Almost have it back on the road.

            Comment

            • delamaize
              E30 Fanatic
              • Nov 2013
              • 1429

              #7
              Pretty damn good welding for your first time out!!
              Dumpster Fire Pilot

              Comment

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