First E30 - 316i Touring Rescue - (Update: Now MOT'd!)

Doing a minor build / restoration or an epic one, post it here

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iDemonix
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Sun Sep 22, 2019 2:07 pm

Picked this old beast up:

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And after a few spots on a spare bit of sheet, decided to just give it a go on the car - been a long time since the car had any weight added!

Patch:

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Welding went ok for the first few spots. Then the gas stopped working which meant a few aerated useless spots that had to be ground back. I figured out the issue was due to the torch shroud not being seated correctly, but I turned the gas off whilst fixing this, and forgot turn it back on - more useless spots and lost metal. Not the most successful first (in a while) attempt, but it did teach me to double check things like gas and so on in future, onwards and upwards.

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Not the worst end result, although after lining a rotten wing up I realised it's not far enough down to mount a wing to, so I'll still have to add a bit in future! D'oh. Never mind though, as the main thing I was aiming for is having something to patch up against to when doing the o/s footwell - which is the next job.

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Or at least it will be if get a dry spell. During the rain going to finish the front callipers and either get these bits powder coated next week, or wheel + paint them in the garage. Typical the sunny spell of hot weather ends when the new welder arrives...
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Mon Sep 23, 2019 10:53 am

Guy up here in Edinburgh has broke a 318i touring i bought some parts off of him and he has a valance in quite good condition slight rust on the edges inside but not severe and priced at £75 he also has a lot of other bits

https://www.gumtree.com/p/car-replaceme ... 1353137395
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iDemonix
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Mon Sep 23, 2019 11:54 am

Thanks for the link mate!

I'm going to nudge this bloody FB guy again, then lose patience!

Bump stops + gaiters have arrived today, springs have been dispatched (from Poland, mind) so once they're here then it's time to put the suspension back on (whether it's powdered or painted) and then I really need panels!
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Mon Sep 23, 2019 12:48 pm

Good luck
Your builds coming along well still to start mine (Touring) just waiting for the sparky to wire the workshop
Finished colllecting parts so will hunker down for the winter and make a start
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Mon Sep 23, 2019 8:43 pm

Brigates967 wrote:
Mon Sep 23, 2019 10:53 am
Guy up here in Edinburgh has broke a 318i touring i bought some parts off of him and he has a valance in quite good condition slight rust on the edges inside but not severe and priced at £75 he also has a lot of other bits

https://www.gumtree.com/p/car-replaceme ... 1353137395
You in Edinburgh too? I am. Green Touring. That guy Murray didn’t reply to my parts request although I have dealt with him before and he’s a good lad.
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Tzantushka
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Tue Sep 24, 2019 12:13 pm

Impressive restoration work given the state of the car.

The rust - OMG the rust!
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iDemonix
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Tue Sep 24, 2019 10:16 pm

Teeny tiny update...

Struts dropped at the powdercoaters (finally!!!) and hopefully get them back in a few days, also hoping the springs will make an appearance this week. Apparently it's cheap to buy spring plates + ARB brackets from BMW still so I'll look in to that tmrw, also going to replace the ARB instead of get the old one painted.

Anyway, the weather this week is crap, but the rain stopped for an hour after work so I decided to have a quick go...

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Not perfect, cocked the ones up along the top and blew a hole, but I put a piece of copper behind it and built it up to an acceptable level. According to the friend I borrowed the welder off I need a touch more wire speed + power, so I'll test that out next chance.

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Quick blast of weld through primer until the weather subsides and I get another dry hour to carry on.... oh to have an indoor workshop...
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iDemonix
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Wed Sep 25, 2019 9:55 pm

Another hour of dry weather today, and every hour is an hour closer to the MOT slip...

Upped the welder power from 1 to 2 (full range is 6) and tickled the wire speed up.

Few practice spots went ok, so they're the new settings...

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Because there's more power and wire, I don't need to hold the torch on as long, which in theory (I hope) means less blowing holes - which happens fecking quickly on thin metal!!!

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Some Cardboard Aided Design for the remaining hole, not helped by the woefully un-straight edge. I sanded it a bit more with a dremel to get it a bit smoother but it's not amazing.

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Rough template scribed.

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Fettling. The welds don't look that big on the first patch, but there is full penetration, and I added a spot or two where there was a pinhole or where it needed a bit more. Once all the welding is done I'll add any reinforcements needed from underneath, then grind it all, check for pinholes, and repeat until it can be primered, seam sealered, primered again, and then top coated with some cheap rattle can silver.

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After about an hour of messing, I'm left with this, which is held in place on its own without magnets. There's a few flush bits so I think I can tack it in and then repeat the method of hammering all the edges flat enough for a set of spot butt welds. The little hole top right will have to be carefully filled with weld, and the gap on the right edge isn't great so might try and take a bit more off the wall/car first...

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If the poxy weather would allow!
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Wed Sep 25, 2019 11:50 pm

Looking good (not the weather forecast). Are you a first time welder?
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iDemonix
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Thu Sep 26, 2019 12:03 am

Yup. I'm aware it shows!

I'm practicing on the more hidden bits first before I have to tackle anything visible like the sills. The first patch of the footwell above doesn't look great but underneath it's joined almost perfect, exception being the top edge which will get ground back and redone later.
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Thu Sep 26, 2019 9:47 am

Respect! I'm ok with spanners but I've never attempted fabrication/welding, I know without trying that it wouldn't be my thing!
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iDemonix
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Thu Sep 26, 2019 9:39 pm

Another tiny update, springs arrived, QA assessment again:

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Looking forward to actually bolting some of these to the car...

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Tomorrow I'm picking up brand new ARB brackets + spring plates from BMW, and I've bought a good condition 20mm front ARB off of an FB Zoner (and bonus it's red, which I wanted) so that should arrive next week, and then it can get some wheels back on it! Just need to order braided hoses and then that's everything really but the copper tubing (which I might leave until after the MOT if I can) ready to go.

Spent another half hour fettling the car and patch panel before deciding it was close enough to tack + hammer flat.

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The rain started again, so sadly this is as far as I got. Not pretty but it's better on power setting 2 and wire speed almost 3. I had to fill a few pinholes last time but can't see any this time, and it's beaded up nicely both sides. Once I get another dry spell I can finish the remaining weld, then grind it all back and add to, then get it sealer'd and painted.

If this was an M3 resto I wouldn't be happy with how it looks, but I (and my missus) keep reminding myself that I bought this car for £250 to learn to weld/restore, so this is the time to practice. It does give me some confidence I can absolutely batter the living daylights out of the panel with a lump hammer to reshape it and it's solid, can't wait to have completed patching a hole.

Apparently it's rain all day tomorrow, but Saturday should be mostly dry, so I'm hoping to finish the o/s footwell and then pick between doing the n/s footwell next, or the o/s inner arch as then that side is ready for suspension, brakes, inner arch liner, and a wing bolting to it (when I source one...) and it'll just be the sill on the o/s to do.

Baby steps...
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iDemonix
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Sat Sep 28, 2019 6:58 pm

Well today's forecast might as well have been presented by Michael Fish. The 10 hours of dry weather turned out to be 3 hours, with patches of rain in between. I wish I'd started this effort a couple of months ago...

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All welded up and ground back. Doing the edge where it meets the wall wasn't fun, but I patched all the holes. Annoyingly I found a tiny pinhole where the two patches met, went to drop a tiny tack on it and blew a big hole. Another half hour sorting that...

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Feels bizarre to look in to a footwell and not see all the light pouring in from the hole. Not perfect, but it should last the life of the car IMO.

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Some of the meeting points were so neat I almost wanted to not seam seal it...

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But, I'm not taking any chances:

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Using Tiger Seal, which on the stuff I welded a year ago still seems to be doing its job just fine.

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Primered, just waiting for some black stonechip to arrive, then it'll get a layer of that, with a layer of waxoyl underseal on top. That should keep the metal protected for a long time hopefully.

Decided to blast some epoxy on the new ARB brackets

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Looking forward to getting some paint on it, even if it's only cheap aerosol stuff, as in the pouring rain some rust has appeared... not sure if this just needs a light sand off or another strip to bare metal + re-primer.

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With the drivers side done, the passenger side can have some cardboard aided design, and some tidying up of edges.

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Getting through stacks of these...

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This patch is good enough for the ol' tack it and wack it method that seems to be working for me...

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Wheeled the welder round to the n/s of the car and then it poured with rain again, so that's the next job when it's dry.

And once the floors are done, I get to pick between moving ABS units and repairing both inner wings, or attempting the sills. I'm not sure whether I should try and patch this like I have been doing, or buy some pattern sill panels and cut them for patches, suggestions on a postcard...

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iDemonix
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Sat Sep 28, 2019 11:00 pm

On a side note, when trying to figure out how to weld, I spent a fair bit of time watching YouTube videos so that I could compare my work.

I found someone doing the same kind of repairs and on an E30 too:

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After he did the above, he primer + painted it and called it a day. If this is what's generally accepted then I'm fairly pleased with what I've done.

At least he'll get to make a part 2 in a year when it's rusted again.
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Foe
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Sun Sep 29, 2019 11:17 pm

You're doing a grand job!
And that YouTube is not acceptable!
It's been tack welded, I'm sure, hope he goes back to finish it!!
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Brianmoooore
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Sun Sep 29, 2019 11:24 pm

Foe wrote:
Sun Sep 29, 2019 11:17 pm
You're doing a grand job!
And that YouTube is not acceptable!
It's been tack welded, I'm sure, hope he goes back to finish it!!
UK MOT test regulations require rust holes in sheet steel to be repaired with a continuous bead of weld if within 300mm (?) of a suspension mounting point, which I'm sure some of those welds are.
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iDemonix
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Sun Sep 29, 2019 11:48 pm

Foe wrote:
Sun Sep 29, 2019 11:17 pm
You're doing a grand job!
And that YouTube is not acceptable!
It's been tack welded, I'm sure, hope he goes back to finish it!!
Thanks :) All motivation appreciated as the nights are getting shorter, rain getting more often, and enthusiasm starting to fade - I'm sure all will be reversed once holes are patched, new parts are on, and someone finally sells me some silver panels.

The dangerous thing about YT is anyone can make a channel, I too would like to hope he'd have finished what he started, but nope, por-15 and seam sealer, job done!

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Madness. Feel better about mine!

Potentially dry days are Wed-Fri, lots of cutting, patching, welding, and assembling (if the powdercoater rings and says they're done) to do.

Quick update, spray painted the footwell with 151 silver aerosol and put the vents back, clipped cables in to holders, that footwell has looked so depressing for years.

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Cleaned a few bits whilst it was raining, apparently problems with the hazards/indicators can be caused by a broken glovebox light, but that works fine. Tried to get the steering column cowling off but couldn't, googling reveals that the steering wheel has to come off, yay! More jobs for next week.
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Mon Sep 30, 2019 12:14 am

That looks the business :thumb:
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AndyB
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Mon Sep 30, 2019 9:41 am

Your doing a grand job
My problem is I don't clean as I go and end up working in a mess

I'm enjoying your build as we are at similar points but I see you steaming ahead soon as I only get Saturdays to work on it

Keep going it gives me drive
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iDemonix
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Mon Sep 30, 2019 10:20 am

AndyB wrote:
Mon Sep 30, 2019 9:41 am
Your doing a grand job
My problem is I don't clean as I go and end up working in a mess

I'm enjoying your build as we are at similar points but I see you steaming ahead soon as I only get Saturdays to work on it

Keep going it gives me drive
To be honest I only get weekends too now, as the evenings are now too dark by 18:30 so there's barely time to wheel the welder out after work, and I tend to only use the power tools at weekends, not nights, as I live on a typical urban estate with houses full of kids all around.

Sat looking at the lovely clear sky and sun today, annoyed knowing that in 5-6 hours it'll be raining when I get home!
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AndyB
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Mon Sep 30, 2019 11:49 am

Yeh know the feeling
I'm thinking if getting a rechargable work light so I can at least do something after work to push things along

I might have a big day of cutting out Saturday so i can at least do a bit of welding in the evenings maybe
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vurso
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Tue Oct 01, 2019 2:07 pm

Brilliant build thread, tackling similar areas at the moment.

I've subscribed and looking forward to future updates!! Maybe a small marquee / gazebo or similar may help for these wetter days we are having?

I'd hate to be trying to tackle my project outside! Fair play to you!
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boiliebasher
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Tue Oct 01, 2019 7:14 pm

Yes indeed, fantastic thread! Keep up the great work :D
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iDemonix
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Wed Oct 02, 2019 8:03 pm

Goodbye old office...

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Hello new office :mad:

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The patch from the last post got put in by personal method of Tack-it 'n' Whack-it™

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Grind it back and fix any issues...

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The plan was to batter this bit upwards for the curve, but it's too short...

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So out with the angle grinder, and chop it straight instead.

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Left for tomorrow:

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Much like the other side's process, we now have a smaller hole to patch. Ran out of light, hopefully there's more dry weather tomorrow and I'll try and get the edges cleaned up and the new template at least cut and almost ready for fitting, then I need to cut a load off from the outside and sort out the mount point for the exterior wing. Once they're done it's welding of the inner wings themselves, then sills, ugh... it feels worse typing it all out - I haven't even looked at the rear end of the car yet and it's getting cold, wet, and dark!

In other news, my free labour sprayed the chassis in cheap 151 aerosol paint - which I ordered nowhere near enough of, so we ran out - more on order ASAP. The subframe got a wirewheel blast and then a layer of stonechip, will take a pic of that tomorrow.

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Think within a week I'll get the belts changed, radiator on (no fan for now) and start 'er up just to make sure it still turns over, and to see if the squealing was belts or bearings from a pump/alternator.

Some Oreo's arrived from BMW... you can't polish a turd...

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But, you can roll it in glitter (and silver metallic aerosol)

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More other bits, the ARB arrived and is mint (it's not cracked, it's grease), but I'll use the new bushes I bought instead of these 2nd hand unbranded ones:

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Glad I sprang for a new kidney grille instead of painting the cracked shit one I had, looks great

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The rest of the grill has been cleaned with soap + water, and I think I'll key it up with 1000 sandpaper and then paint it in satin black (or should I not sand it first?)

The carpet dye arrived, shampooed the carpets first and then tested the dye on the boot panels first (as well as my grass, patio, and legs) before doing the main carpet:

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Good enough for me. The only criticism is it makes the carpet a bit stiffer, but I'll buy a tough brush and give them a proper brush down afterwards. Another coat tomorrow, and the first coat on the main carpet if I get time.

This rather weighty bit of bling arrived, might not be to some people's taste but that's never stopped me before. There won't be any other hints of stripe on the car - unless it gets a big beasty engine in future...

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Few other new minor bits have arrived like the U drop link brackets for the ARB, pics of them during the build phase, which is coming as soon as my powder coater get back to me, apparently they were finished today but some of the paint didn't adhere to a corroded part (despite 2-3 days in an acid bath and sandblasting) so they said they'd do them again this week. Once they're back, dampers in, springs on, and start getting all the rolling bits on the front of the car - although rushing to do the welding/painting in this area first so as not to ruin the new shiny bits.

I still hate welding.
Last edited by iDemonix on Wed Oct 02, 2019 10:24 pm, edited 3 times in total.
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brutus
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Wed Oct 02, 2019 9:11 pm

yes all impressive work. mate

:thumb:
MANY e30 PARTS FOR SALE.
( all models available )
& parts /glass for e21, e28, e34, e36,e39,e46


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iDemonix
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Thu Oct 03, 2019 2:32 pm

Well the new flasher relay came, albeit with too many pins (4 instead of 3), but sadly swapping them gives me the same issue with just a new type of click. At least I get to choose which sound I prefer...

Old:



New:



Anyone have any ideas before I have to go troubleshooting through the loom? All the bulbs are present and working, as is the glovebox light (which I've been told the absence of can cause issues)....
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martauto
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Thu Oct 03, 2019 2:36 pm

brutus wrote:
Wed Oct 02, 2019 9:11 pm
yes all impressive work. mate

:thumb:
I am loving this mate !!
40 years younger , if only lol

Mart.
Only the E46 cab left now.
Just got too old.
stones
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Thu Oct 03, 2019 2:57 pm

iDemonix wrote:
Thu Oct 03, 2019 2:32 pm
Well the new flasher relay came, albeit with too many pins (4 instead of 3), but sadly swapping them gives me the same issue with just a new type of click. At least I get to choose which sound I prefer...

Old:



New:



Anyone have any ideas before I have to go troubleshooting through the loom? All the bulbs are present and working, as is the glovebox light (which I've been told the absence of can cause issues)....
Is this a new problem or was it happening before you started working on the car?
Do any indicators flash? That fast indicator ticking can be because a bulb has blown or is missing, as you have the wings removed have you put the bulbs back into the indicators on the wings? (side repeaters)
HTH :)

Also enjoying the updates. Good work especially with the weather. :thumb:
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iDemonix
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Thu Oct 03, 2019 3:45 pm

stones wrote:
Thu Oct 03, 2019 2:57 pm
Is this a new problem or was it happening before you started working on the car?
Do any indicators flash? That fast indicator ticking can be because a bulb has blown or is missing, as you have the wings removed have you put the bulbs back into the indicators on the wings? (side repeaters)
HTH :)

Also enjoying the updates. Good work especially with the weather. :thumb:
It's a problem that's existed since I picked it up, everything works as expected - it just flashes too quickly when on indicators, hazards work fine. I've swapped out the front indicators with new bulbs, not swapped the rears yet but they light up as expected so not sure that'll fix it either.

Could it be to do with a bad earth somewhere, and does anyone have a list of M40 touring earth points I could go through and check? Was proper praying the relay was the fault, nothing like sitting with a light up screwdriver for hours tracing gremlins...
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boiliebasher
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Thu Oct 03, 2019 4:24 pm

Mine did exactly the same thing when I forgot to put back one of the rear bulb holders/ cluster.
Double check rear clusters and bulbs, see if there's anything wrong there.

Do ALL brake/tail/indicators/ lights work on the car?!
stones
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Thu Oct 03, 2019 4:46 pm

Earth/Ground points to check are on the Passenger side wing (behind your ABS unit)
Behind the glove box
Rear passenger side wheel arch just above the rear strut top mount.
Link to the wiki wiring diagrams, slightly different to Tourings but good enough.
https://www.e30zone.net/e30wiki/index.p ... g_Diagrams
HTH :)
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iDemonix
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Sat Oct 05, 2019 9:17 pm

Ignoring the electrical gremlins for now, back to the metalwork...

Here's the victim:

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Tack-it 'n' Whack-it™...

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A load of swearing and many hours later:

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Note for future reference: best settings for this are power on 1, wire speed just under 3, gas rate on 15L/min. Power on 2 just kept blowing holes, given up on that now and seem to be slowly getting the hang of it, with the odd hole and pinhole here and there to fix.

Seam sealer drying ready for more primer + top coat tomorrow, speaking of which, I will be driving a 600 mile round trip to go and get a pair of wings + valance, one wing isn't very usable but a good silver valance is really what I'm after and if the wings can get through an MOT then they're getting bolted on.

Few steps forward and back in other places, struts are back from the coater:

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Set the rebuild station up with all-your-savings worth of new parts, noting that she's certainly going to sit lower:

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Regret using masking tape, this took 30 minutes with wire wool, a razor blade, and patience, to remove:

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And then realise the fecking dust ring/seal/washer things are the wrong size:

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D'oh, that's them not getting rebuild yet then.

Never mind, I'll do the brakes...

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FML. Seals and dust cover are too big, another part to re-order in the right size...

Now angry, I decided to tackle the remaining track rod. My friend had spent 1-2h beating it but it still hadn't freed up, so it got a minute under the blowtorch, an adjustable spanner put on, and then a massive boot from my foot which finally released it:

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Won't fit the new ones until all the welding/spraying is done around the front end.

Another quick job, new belts fitted which will hopefully stop the squeal it had.

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I was going to refit the rad and its cowling to fire the engine up, but I can't remember what kind of clips these used, or locate any spare that would fit, might have to dig through diagrams/images:

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I decided not to replace the radiator, despite it looking awful, as it's a "with an engine swap" job. I did blow it out with an air gun and some lovely hard lumps came out:

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The throttle clip has always been broken and fallen out as soon as you use the pedal, I bought one of these, then realised you need two and they clip together and ordered the second:

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Whilst in the engine bay, noticed the ABS unit isn't looking too healthy:

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New bits on the ARB, using the Febi bushes I bought instead of the tough Powerflex ones that came with it:

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For the last bit today, gave the carpet its 2nd dye although really it hasn't changed it much:

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Picture of the car with no holes in the floor, finally:

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Now, off to bed for an early night so I can get on with the joyous 600 mile round trip for some ok-ish panels... remind me when projects become fun again?
TeddyK
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Mon Oct 07, 2019 12:00 pm

Fantastic thread!

I've just read through it all whilst I was bored at work and have decided I need to post an update on mine ASAP when I get home.

Where did you get the carpet dye from? And is it a brush on type or a spray type?

I'm going to be dying the carpet black in my 316i Touring at some point over this winter too!

Cheers,

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iDemonix
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Mon Oct 07, 2019 1:20 pm

TeddyK wrote:
Mon Oct 07, 2019 12:00 pm
Where did you get the carpet dye from? And is it a brush on type or a spray type?
Thanks TeddyK.

The dye is a 5L bottle called "Valeters Pride", if you search it on eBay you'll find it. It goes on with a hand-operated spray bottle which you can see in the last pic, for an extra few quid on eBay they will include one (and a sponge). Took 10 minutes to do each item, and tbh I don't really think the 2nd coat was necessary - I just did it as I still have half the big bottle left.
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Thu Oct 10, 2019 8:21 am

As ever loving the updates.

I’m learning about welding as I go too and was thinking if your welder was hotter setting and slower wire feed would the metal melt into the gap better so not so raised and less grinding?

I’ve had some nice welds and poor welds on the same setting.
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