Thu Jun 23, 2011 10:53 pm
I'll give you some places to look for rust: You probably know typical facelift rust problem around the rear towing hook, then there's behind ALL wheels, sealer might look nice, but there can be trouble underneath. And then there's is the sunroof problem. As you probably guessed by now I've been in your position.
Now I didn't remove the carpet until after metalwork and paint. It all looks great under it, I was changing cable harnesses, I found that were they all meet in the footwell of the passengerside and go up into the IP basically were the cables come out of the slot in the inside sill and bend 90 deg they cross a big bead of sealer on the sill. I had spotted some rust there, thought it was surface rust. But it was much worse. Inside the sill the drainpipe from the sunroof comes down and lets the water out into the sill right there, so here the inside sill was rusted through inside out. This applies both sides, basically look at the inside sill under the speakers and remember to lift the wireharnesses up and look under them too. If that big sealerbead looks at all loose, bumpy or has cracks there is potiential trouble.
I have learned 3 things from my restauration work (it's my first project):
1. Don't remove the doors by unscrewing the 4 nuts that hold the hinges onto the door, that will be a pain to get right, I'm almost there after several months now, still have to do some fine tuning on the driversside, my car being a 4 door. I even managed to snap one of the studs in the passenger door, so had to drill a hole in the remains and make thread in it so a M5 bolt could be used. Instead part the hinge by removing the 1 bolt that holds it together, it so easy, but Haynes says remove the 4 nuts, idiots! I'm going to throw my Haynes manual in the fire soon, it's worthless when you have some knowledge of how a E30 are to fix.
2. Find a seriously skilled and trustworthy bodyshop to do the bodywork, if you can't do it yourself.
3. ALLWAYS remove the carpet when doing a resto project. There can be nasty things under there, and changing wireharnesses with the carpet in is a nightmare.
Why is there not enough time to do it right, but allways enough time to fix the errors - I borrowed that, just so reallistic in my line of work.