User Profile

[Sunnyledge]

5/16 copper nickel is a near match of the factory BMW steel fuel lines. A little harder to bend that the 3/16 tubing and so the tubing bender came in handy. Go slow or it can kink. The only challenging...

[Sunnyledge]

I went with a new brass junction block up under the rear end and all new soft brake lines. New wheel cylinders, brake shoe and drums completed the rear set up....

[Sunnyledge]

I first created the tubing sections using the lengths listed with the part numbers found on the various online BMW parts sites. Here is a 560 mm brake line and the 3120 mm main brake line. Some of the...

[Sunnyledge]

I initially thought I would purchase the factory BMW lines. Total cost was going to be $300-400 for the hard brake and fuel lines. But I became concerned that I might not be able to make some of the tight...

[Sunnyledge]

In order to make the previous repair I removed the gas tank so I had a prime opportunity to replace the hard brake and fuel lines which suffered from rust. The main brake line had a patch with compressing...

Are you still looking for this info. The front of my car is disassembled.

[Sunnyledge]

What year is your car? The bumper shocks differ depending on the year of the car. 84-87 uses one type, then 87-88 another, and 89 on.

[Sunnyledge]

Welding completed and in epoxy primer....

[Sunnyledge]

Three pieces needed to be fabricated in order to complete the repair....

[Sunnyledge]

One last little rust repair to show, thought there we many others. The left rear wheel well had rusted through. While not overly important structurally, I couldn’t ignore it....

[Sunnyledge]

The left side suffered greater damage, affecting all three structural layers. So repair one patch or layer at a time trying to maintain some of the damaged metal to help with proper alignment of the patches....

[Sunnyledge]

I located a factory replacement panels, what BMW calls a side member. I decided not to separate all the factory weld and replace the entire panel, but to use it as a patch....

[Sunnyledge]

The right rear involved some minor rust damage to the outer rocker. I traced the profile of the damaged segment onto a piece of hard maple, cut and shaped the profile I was looking to achieve and used...

[Sunnyledge]

The rear inner rockers were also badly rusted and certainly a structural concern....

[Sunnyledge]

After finishing these two repair I created a 3-D collage titled “Henna Rot”. (Giving new meaning to Hennarot). Don’t think I’ll get $120,000 like that guy did for taping a banana to a wall....

[Sunnyledge]

I also repaired the drivers rear rocker. As it was beginning to get cool I decided to put off paint until the spring....

[Sunnyledge]

Clamps, welds, grinding and the repair is complete. Since the majority of the welding is hidden by the bumper trim and stone guard you don’t need to get super picky. A little filler on the repair...

[Sunnyledge]

I also needed to reconstruct the inner wheel well. And a little patch to the wheel arch....

[Sunnyledge]

The panel for the “trunk well” is NLA (although there is now an overseas source). Template, rough panel, a couple of beads to add strength (and cause it looks neat) and a few bends....

[Sunnyledge]

First came a patch to the rear valance which was fairly simple. Just need to connect all the welds....