S38B36 Laguna Touring

[ceige85]

Very nice work dude! Ive used some bilthamber stuff for the rust on mine, its a gel that takes it back to shiny metal and is actually amazing stuff!

[martauto]

No mate, take your time,why not do another one as well to keep us occupied??

Mart.

[lellis]

Very nice work dude! Ive used some bilthamber stuff for the rust on mine, its a gel that takes it back to shiny metal and is actually amazing stuff!

sounds like a good product, mine seems to need a few extra steps than that

[lellis]

Quick little project, driveshafts!











A vid for anyone interested as always

[lellis]

Diff rebuild in next

[lellis]

Had a friend come over and he brought his 35mm with him

[lellis]

The diff is done! May of took a bit longer than planned, but it's done..

So it's a 188mm 3.15 LSD from a 2.8 Z3, it has the fancy 4 clutch plate carrier unit. I've added the e36 rear cover for the twin ear design, will modify the car to suit.

Here are some pics, easily my most rewarding resto yet.











And the before

[AlexD911]

Nice where did you buy the new diff from?

[spannerrash]

Looks amazing as always. I trust the internals went back together well nicely? I'm hoping you'll do a vid on this as I've got an LSD to rebuild at some point too. Not as fancy as yours though.

[lellis]

Looks amazing as always. I trust the internals went back together well nicely? I'm hoping you'll do a vid on this as I've got an LSD to rebuild at some point too. Not as fancy as yours though.

Yes! just finishing off the video now, haven't had time (energy) to edit it yet..
It'll be a long one for sure

[spannerrash]

Awesome, I look forward to that going live.

[lellis]

bit of a underside update as of yet:













Then it was starting on the larger pieces,



First I tried to make this part out of one, but no way that was working



Aiming to keep it looking as oem as possible without buying new panels..

[martauto]

Great work again mate, I love your approach to the fabrication, a bit of "CAD" as well
Will you store it for the autumn/winter or just keep going on her ?

Mart,

[lellis]

Great work again mate, I love your approach to the fabrication, a bit of "CAD" as well
Will you store it for the autumn/winter or just keep going on her ?

Mart,

CAD is the way!

I'll keep it going, need it done asap really.. Hoping for a rolling chassis by the end of the year, will try my best anyway

[lellis]

Few more bits made and mocked up before the rest is removed


More patching


I got a bit excited and removed the beam without making the other side of the first pic.. Will sort that issue later


Now the other side of the chassis rail can come out, I decided to do one at a time in case the car bent in half


Next is to keep chopping until the rust stops, especially around the seat belt mounts


Some serious metal removed here, only bits being reused are the spring perch supports..

[AlexD911]

Thats a proper job mate! Well worth the peace of mind that comes with it!

Alex

[The_Glory]

Good motor. Good body work.

[HartgeRaul]

I like all the up grade parts. Keep the up dates coming.

I’m still working on my s38 e30

[lellis]

A complete restoration of my 188mm limited slip diff video just posted on my YouTube!

This one is particularly special being a 3.15 from a z3 with extra clutch plates.

All parts and specs posted in the description for anyone interested in doing the same.

[lellis]

I like all the up grade parts. Keep the up dates coming.

I’m still working on my s38 e30

I haven’t had too much time on it recently as my house renovations has took priority..

I do have some questions for you regarding s38’s in e30’s and i know you’re the man who has the knowledge.

I’m looking for a carbon airbox intake (like s54 csl), I know there are ones for e34 m5’s but wondering if you know of someone who has tried and whether they fit. I really don’t want to add a bulge to the bonnet but happy to cut away at the internal supports

[lellis]

As always, not much to update..

I started work on removing and replacing the ARB/diff mounting beam.

I do love my spot weld drill bit




Tiny repair to do on the chassis rail, but mostly ready for new pieces.


Next was finishing this big old task that didn't mean to be so thorough..

All these pieces were remade by myself


A few before, during and after pics






img]https://live.staticflickr.com/65535/529 ... 8469_c.jpg[/img]

[Tzantushka]

Impressive work!

[martauto]

Impressive work!

X 2

Mart.

[HartgeRaul]

I’m impressed of your work and patients you have!!!

[lellis]

Thanks guys!

I now have a decent chunk of shift work on I thought I'd update where I got to in the last couple days.

starting with the front footwell 'patch'.


Turns out it didn't do too well at stopping the rust..


Three pieces worth were chopped out, and surface rusted seams were cleaned and rust converted.


Bit of CAD


First mock up with all pieces


Plug weld holes made, the curved piece had a internal flange to weld to the sill too


Bit shoddy on my grinding, but the underseal will cover my mistakes..


Moving swiftly onto this rear pocket (or what is left of it)


6 pieces removed here


Hammer, vise and a rounded off bolt to mimic the original shape


first mock up, few more bits to make and shaping to do.

[fixedwheelnut]

I pray you finish this build before I die because this is epic and I want to see it

M30 engine you can get a hot climate water pump pulley and belt, might be similar for the S38 to help with cooling.

pulley 11511271423
belt 11231711090

[lellis]

I pray you finish this build before I die because this is epic and I want to see it

M30 engine you can get a hot climate water pump pulley and belt, might be similar for the S38 to help with cooling.

pulley 11511271423
belt 11231711090

Steve, if it isn’t done by next year I’ll probably die..
I’ll be sure to pop over and see you and your car!

Good suggestion on the pump, but I’m pretty certain the s38 but is already better flowing. The pulley may be handy!! Will look into that.

Thanks

[lellis]

Back to work for a few days, had some pretty serious progress on my time off.

Made this contraption, i need to replace the rear valance for a twin exhaust style, plus a ton of rust repairs.
This allows me to remove the rear support of the jig and move the support to the chassis rails in the boot.



I definitely shouldn't have done this on my own..


But it worked! Luckily I had this planned when initially building the roll-over jig, so the supports were easily removed once the weight was taken up.




Then straight into the removal process








Now waiting on the valance to arrive, so I can start mocking up the repair pieces, currently around 5 pieces to do and all not too crazy complexity.

[martauto]

You have much bigger balls than a lot of us !!!
I`m glad you think what to come is easy ,it would scare the crap out of me
Looking very good mate, hope the weather holds for you !!

Mart.

[lellis]

You have much bigger balls than a lot of us !!!
I`m glad you think what to come is easy ,it would scare the crap out of me
Looking very good mate, hope the weather holds for you !!

Mart.

It may look like smooth sailing, but in reality it isn’t that easy. A lot of prep work and research first before i dare take the grinder to anything. Then a ton of photos at each step for me to understand how it all goes back together!

[spannerrash]

Seriously impressed with the quality of the repairs you're doing. Mine have been a bit more on the "that'll do" side compared to these.

The body will literally be as good as if not better than new when you're done. Great progress!

[lellis]

Seriously impressed with the quality of the repairs you're doing. Mine have been a bit more on the "that'll do" side compared to these.

The body will literally be as good as if not better than new when you're done. Great progress!

Thanks! Sometimes I wish I could make my life easier and get away with a quick repair, but being this deep into it my brain just won't let me!!

Trying to keep it as OEM as possible, definitely adds to the complexity of it all..

[lellis]

The new panel arrived the other day and I got straight into cutting it in half (if anyone wants the top half for a non-touring facelift model) it's yours, collection in Nottingham.


Both bumper mounts removed and remade, including part of the chassis rails.


Mocked up the panel, aligned with original body lines, and cut to shape.


Marked the mounting holes and drilled to size.


Bolted on, now I can carry on with the rear pocket and tow hook repair.

[martauto]

Awesome work mate, wish I could do this, keep going

Mart.

[lellis]

Busy few days on the rear,

Made up a new tow hook bracket, but decided to not use it. Too much of a rust trap, and if I ever need to pull the car from the rear, I am sure it'll be in such a state where it doesn't matter where it is held from..


With the valance mocked up, I was able to start on the rear pocket repair.




Not bad for a first try.


A lot of welding (and waiting for it to cool) later, it was on. No excessive warping and all the gaps look good.


Ground down most of the welds, all will be hidden anyway. 2k epoxy primer'd.


I really like how factory fresh this primer makes everything look.




Now back to the rest of it..