S38B36 Laguna Touring

[martauto]

It`s a real shame about the towing bracket as it looks spot on .
Thank God for CAD though !!!

Mart.

[lellis]

It`s a real shame about the towing bracket as it looks spot on .
Thank God for CAD though !!!

Mart.

Yeh I was very close to using it, trying to keep it OEM as possible but sometimes it is best to change designs due to known issues!

[lellis]

Here is the video of the complete process for anyone interested in tackling the same task.

[lellis]

Another couple good days,





7 pieces in this!










No saving the drain here, so act like it was never there


Rear section finished (weird actually saying something is finished) 19 pieces in total (including valance repair). All epoxy primered to help me visualise the progress I am making

[lellis]

Back at work, been off since the 4th so had some serious time to get on with the car, and that is exactly what I have been doing!

First on the list was installing the newly made cross member and everything to go with it.


Moving onto the diff mounting, I am going with the e36 twin ear setup.
Mounted the subframe and diff and set to the correct height. I made these mounts up and cut to suit, with spreader.




Test fitted after welding


Here is a video of the whole process.

[lellis]

I noticed the subframe (with reinforcement plates) was pretty close to contacting the seatbelt mount cross member, bit of heat and 'shaping' later.


A load of small patches for underneath the fuel tank later and it was time for paint. Including about 150mm of the handbrake pipes.




Rear wheel well brackets replaced, also some studs. The metal pipe that carries the vapour piping has been replaced too.


A bit more under the fuel tank, quite a lot of little areas with a lot of layers! Now up to the floor area.


Then working on the middle section, all sill 'jacking points' that will not be used have been replaced.


The patching over the factory drain holes.


I have a little bit more to do on the middle section, then front wheel wells and it is ready for underseal!

[lellis]

Carrying on,


Also cut out the part of the chassis legs that protrude under the front floor, straightened them back out and welded back in. A nice simple task rather than making new!
Repaired both outer seatbelt mounting plates, filled a few more drain holes, new studs, fuel line bracket studs, sill jacking points etc etc.


So that is another section done! 3/4 of the way through..

[fixedwheelnut]

I am so in awe of your level to detail Liam, fantastic work this is going to be epic once finished

[lellis]

I am so in awe of your level to detail Liam, fantastic work this is going to be epic once finished

Thanks as always Steve.
Very excited to get the underseal on and start moving onto the next steps!

Always like to go back to the start when I got the car on the jig for the first time, crazy to see the difference!

[martauto]

Well Liam, this is something I would still love to do but Oldness has crept in so watching other guy`s do it the way I would is a lot better for me right now lol.
I love it when people take their time and do research before ripping into stuff.
NICE ONE mate

Mart.

[lellis]

So as this project progresses, my standards increase.
Coming to the end of the underside, I am back to where I first started the journey. And this needed addressing.


Remaking it all.




This is when I had a plan, add some shape. I had a friend help bead-roll the panel, then I turned a die to press a dimple as a water drain.




Now it looks less stance-boy and more oem plus?? maybe...


After welding in and smoothing.


Shape copied and transferred onto the other side.


A bit messy under here due to cutting it up twice...
Now to figure out where the tabs for the valance and arch liner go.


Oh, and another friend helped finish the arch repair. Sometimes it is best to leave it to the professionals.

[lellis]

So I cut this hole many years ago with a plan, however never seemed to finish it..


This needed to be done so I can do the underseal. Plan was to 'redesign' the area so there is no sign of a battery tray, I know people cut the tray out but then leave the flat inner section.

Using the original panel that was upright, I added some extension pieces and mounted it at an angle to the firewall.


Then proceeded to fill in the gaps.






Holes to be made once I have mocked up the pedal box and a few other bits. Happy with the outcome, wish it was a bit more OEM but it is something different..

[DanThe]

Battery tray delete looks like it was meant to be, very nice job on the arch repair too

[lellis]

Battery tray delete looks like it was meant to be, very nice job on the arch repair too

Thanks Dan
I find it rather tricky when adding new panels to keep away from the stance boy - flat panel everything look..

[martauto]

Battery tray delete looks like it was meant to be, very nice job on the arch repair too

This goes for me as well, great vision mate !!

Mart.

[DanThe]

Battery tray delete looks like it was meant to be, very nice job on the arch repair too

Thanks Dan
I find it rather tricky when adding new panels to keep away from the stance boy - flat panel everything look..

Im sure that will phase out with age

[lellis]

Easily my most productive weekend I have ever had on the car.

Friday:
Underside repairs completed and primed.






Saturday:
Car scotched down to key surface and wiped, brushed on the seam sealer for the whole car.


Masked up.


Sunday:
Started on the DIY 'spray booth'


Double sealed the gazebo, the started on the underseal.




Two coats of 2k satin paint, and dismantle the gazebo!


More pictures to come once masking removed and in the daylight

[martauto]

Hell this is soooooooooooo cool mate !!!
Bet you are still smiling

Mart.

[spannerrash]

Amazing result, better than OE. I bet youre starting to see the light now the underside is properly coated!

[lellis]

Amazing result, better than OE. I bet youre starting to see the light now the underside is properly coated!

Thanks man. Absolutely exhausted.
But yes, there is definitely a feeling of satisfaction to how far I have gotten recently

[lellis]

Hell this is soooooooooooo cool mate !!!
Bet you are still smiling

Mart.

Thanks dude, so happy with it!
Time to clean up and blow over the interior, then I can start bolting bits back on.

[lellis]

De-masked and in the daylight




Other than the modifications; I am confident to say you would never notice what has been replaced and what is original, there are over 100 homemade pieces in it too.

Some before and afters.

[Tzantushka]

Seriously impressive - well done.

[martauto]

Fantastic mate
Research and preparation paid off big time, well done that man.
Cant wait to see it finished,no.....how you get there will be interesting too.

Mart.

[lellis]

Fantastic mate
Research and preparation paid off big time, well done that man.
Cant wait to see it finished,no.....how you get there will be interesting too.

Mart.

Cheers Mart.
I'm just prepping on what to prioritise on to get the 'wheels in motion'.
Really want it off the jig by the end of the year so I can start on getting the engine and ancillaires to fit!

[boiliebasher]

What an epic build

[lellis]

I haven't had any time to do more car stuff recently, but for anyone interested in more info here is the youtube vid of the whole underseal process.

[lellis]

Back to the messy work!
The inside now needs a good coat of looking at. Starting with the removal of sound deadening. First I finished removing the interior components such as the fan box, steering rack and all the clips and connectors.





I have kind of neglected the inside, not all welds have been protected or smoothed, so this will be the main priority.
A heat gun, scraper and then white spirit and scotch pads is all it took, plus a few hours.





Not the best photos, but that worked better than expected! I also removed the bad sealant left around some of the welds and seams.
Now to attack the welds and get some epoxy primer down!

Debating whether I go for a full interior respray or just spray can with colour matched paint to cover freshly coated areas? I plan on completely covering the floor in sound deadening, weight is not an issue, but extra road noise is..

[lellis]

OEM + out the window. I have wanted a real chunky wheel/tyre combo for a while and have decided give it a go.

Konig Hypergrams, 15x8 et36 fronts, 15x9 et35 rear. A high offset to allow me to space it correctly, tyre wise I am aiming for 225/45 fronts, 245/40 rears..

[martauto]

Not a massive lover of any other colour wheels than silver but these are soooooooooooooo right for the car.
Paint the whole of the inside ............................ you know you want to , just think when it`s all done .....................this will nag you to hell and back if you dont do it now

Mart.

[lellis]

Not a massive lover of any other colour wheels than silver but these are soooooooooooooo right for the car.
Paint the whole of the inside ............................ you know you want to , just think when it`s all done .....................this will nag you to hell and back if you dont do it now

Mart.

So these wheels are 'carbon metallic bronze', supposedly look bronze in the sunlight which is what I wanted but currently I can only see grey.. They did do a silver option too, but they took 3 months to arrive from america so I don't think i can swap em..

And yes you're right, I initially thought there were only a few patches to do in the interior but with the sound deadening removed there is more areas that require paint, so I better do it properly!

[fixedwheelnut]

@Lellis I did the interior floors of mine with Por-15 black for extra rust protection, it's out of sight under the carpet so not a problem really.

Excellent work and I love those wheels

[lellis]

@Lellis I did the interior floors of mine with Por-15 black for extra rust protection, it's out of sight under the carpet so not a problem really.

Excellent work and I love those wheels

Unfortunately my brain won't let me do that:( I have decided to go for the full spray, after working on it today I have noticed there is more than just a few spots to tackle!

[lellis]

After the tedious task of carefully cleaning up the welds, the epoxy primer is on





Now contemplating when to spray, whether to risk it soon with the cold weather so it is done, or wait til spring and move onto other bits! I may need to modify the firewall more due to engine clearances so it may be best to wait til the engine is mocked up.

I have been delaying this job for a very long time now..



Many little bits chopped off, some fancy shapes to now make!



Also forgot to clean up the majority of the bay, so sorted that and primer put on the bare metal. Really not happy with some of the patches I did when I first started many years back..

[lellis]

Right, please someone tell me if I am completely wrong here.
I'm not using the carbon canister in he engine bay, and normally people leave it to vent from that pipe that ends at the bay, so I am still venting the line, but just with the whole line taken out back to the vapour tank. This in theory should suffice, fuel smell may be an issue but it is out the way of the cabin. (Also i know it looks stupid but it is well hidden)



All installed (the sticker residue has been removed since the pic was taken)


Moving straight onto the fuel lines, new pre-bent from bmw that have been post-bent on the way to me..



Sorted easily with a careful massage to the affected area.