Jozi's m52 touring - Rebuilding has started

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Jozi
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Sat Nov 27, 2010 2:06 pm

Thought I'd get a thread started.

Started a job during the summer (what recession!) and what started as tidying up the touring ended up with me buying a m52 when I went to see a guy about a bonnet and boot lid.

I've slowly been collecting parts for the car and for the conversion over the summer. As it stands this is my list:

Here's what I have:

1. Engine, m20 fly (will be lightened) + starter
2. iS rad (prob get a new one)
3. E30 M3 Scorpion exhaust
4. E36 328 loom
5. 3.64 LSD (being rebuilt by Dave)
6. Manifold + sump + TB + Dipsick+ Injectors
7. Rubber engine mounts
8. E34 UJ (x2)
9. Steering spline (from danthe via dave)


And what I still need:

1. 325 Clutch
2. M50 Sump and manifold gaskets
3. Early m50 325i airbox (or move ABS and fit 328 one)
4. e34 525 throttle cable
5. E30 spigot bearing
6. 88 degree thermostat
7. E36 328/325 rad
8. E30 M3 or e36 aircon electric fan
9. Elect fan loom
10. E30 brown temp sensor
11. E36 318ti air-con fan temp switch
12. M50 metal thermostat housing
13. metal impeller water pump
14. Clio Servo
15. Brake master cylinder
16. E30 320 propshaft
17. E30 320 gear shift rods
18. rebuild shift mech with new bushes

Most of it I think is dealer parts.

Will be a slow project as I wanted to sort out rust first before putting the engine in. Work done so far is engine and pretty much everything attached to is is off the car.

Slight change of plan during the week after talking to Scruffymurphy, he's had a touring shell sitting up for ages and was about to scrap it. Couldn't let that happen so picking that up tomorrow. It's a 90 (mines a 94) so easier come nct (mot) and can be insured as a classic.

Plan now is to (probably) clean up the new shell, if I have to I'll cut metal out of my own for it. Either scrap my shell or maybe a trailer :p (or donated it to someone as I rather see it saved than scrapped).

I've got Borbet b's a tec2 kit and iX arch flares and sills to go on as well, not using mtec door pods, on the look out for a tec2 touring spoiler!!!! Depending on money I'll be going looking for coilovers and further down the list is a set of bigger brakes. Will be sticking with mauritius blue unless I get notions for something else.

For the engine I have a m50 inlet got and on the look out for s52 camshafts, I think thats about it.

Here she is with a puddle of coolant under her (m42 profile gasket I think) about 20mins before she got put on axle stands
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This is how far I got:
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---EDIT---

Should really update the above, pretty much have all the parts collected :cool:
Last edited by Jozi on Tue Jun 10, 2014 10:38 pm, edited 18 times in total.
craigieeb
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Sat Nov 27, 2010 5:53 pm

Seem's everyone's going the 24v tourer route

:cool:
M50 Turbo!!! :o I shall say no more :D
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Sat Nov 27, 2010 7:01 pm

Good luck Jozi,itll be well worth the effort :cool:
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Jozi
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Sat Nov 27, 2010 7:25 pm

craigieeb wrote:Seem's everyone's going the 24v tourer route

:cool:
You know it makes sense :thumb:

Thanks Eko, it's going to be a long road but i look forward to it.

Getting thought of dropping the m52 in the touring now. Work on the new shell and re-shell when it's rust free and painted up.
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Mon Nov 29, 2010 4:02 pm

just you wait till you get her in the bay and plumed up, it looks amazing!! 8)
the most satisfying moment for me was the moment i first turned the key and my old girl fired up again but this time a different beast :twisted: , very very self satisfying. Good luck with it mate - Ant :cool:
A 2 door e30 with 8 cylinders, what could be better winkeye :D
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Jozi
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Mon Nov 29, 2010 9:54 pm

Thanks e30-dk. It's going to be a bit rough and ready when i do get round to and I'll do a proper tidy job once the shell is finished and I can move everything over.

Didn't get the shell yesterday, like you guys in the uk, we got a bit of snow and the roads were just to bad to make the drive up to Donegal. Hopefully have it in 2 weeks time.
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Jozi
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Sat Jan 01, 2011 8:16 pm

Not much has happened over the past few months since taking the engine out.

Had intended doing a bit over the xmas break but that didn't happen either. A lot of parts still need to be bought, which I hope will happen over the next week or 2.

I've spend a few hours over the last couple of days getting the m52 ready to into the car, swapped e39 mounting arms for e36 ones, swapped gearbox from the m42 onto the m52, changed sumps and removed the inlet manifold. I'm hoping I can leave the brake booster and few other this where they are for the moment and still have room to put the engine in with the manifold removed.

Tomorrow I'm hoping to get a new touring shell, this has had some welding done already around the engine bay. Hopefully my brother has enough time to do any other required welding around the car by the end of the month when he's of to Oz.

The old touring will get the engine fitted so I can start on the exhaust manifold, could do with some pointers here. I'm trying to decide if I should get the engine running and drive the car again while work is done on the other shell and then just do a swap, more work but at least I won't be driving a micra anymore. Good opportunity to get used to driving it with the m52 and if I have a mishap it's less of an issue than when I'm finished with the whole project.

Also trying to decide if I should fit the m50 manifold now or get it running and see how it drives, I know nothing of the engines history just that it was a replacement engine for a 523. Also looks like I have a set of s50 cams got and hopefully on the post on Monday :D
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Jozi
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Sun Jan 02, 2011 5:18 pm

Little bit of progress today, after a bit of messing with the engine we got it sitting like this:
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Bit of messing to get it on it's mounts in the sub frame but got there in the end. Can start mocking up the manifold next time I'm home and once I get some stainless tubing.

Won't be lifting this engine out though, probably drop the whole subframe, suspension etc and lift the car over the engine.

Got this done instead of getting the new shell today, couldn't go again because they guy lending the trialer and my uncle couldnt get lights working and didnt want to take a chance :(

Engine's normally this black on the inside:
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Exhaust ports have a nice thinck layer of black grime in them as well. Anyway of cleaning this out or what can you do about it?
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Sun Jan 02, 2011 5:24 pm

Mine was a right pain to get on the mounts too, having the m52 gearbox on the back doesn't make it as easy to get it in and out compared to m50 with a m40/2 box on!

How come you need to take the engine out again? I bet your glad to finally see the engine in though :D
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Jozi
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Sun Jan 02, 2011 5:32 pm

No clutch or flywheel on it and will be re-shelling into the touring shell I'm hoping to pickup this week or next. It's really just been put in so I can start on the manifold next time I'm home again and get my brother to weld it for me before he's of to Oz the end of the month.

It's a bit like taking 2 steps in the wrong direction though but I can get other things done while waiting on the other shell. I might even endup driving it for awhile in the blue 94 touring and take my time working on the 90 shell.
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Thu Jan 13, 2011 10:03 am

Hello Jozi,

are you also member of the Dutch e30fansite.nl? I've seen your project, looks nice. I'am also swapping a M50 in my M40 E30!

Do you know that the cheap exhaust manifolds from ebay.de for a M50/M52 will solve the problems with exhaust? From the exhaust manifolds, you can connect it with the cat.? That's the most easy way to make it fit!

I'm looking forward to take my E30 M50 next summer and drive of to Spain :P .

Good luck with the swap!

Groeten
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Jozi
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Thu Jan 13, 2011 9:41 pm

Hi Hulstijn, I am indeed also on e30fansite.nl :) Must update the thread!

I got the shell home just before dark last sunday. Quick glance over it and it looks cleaner than my own :thumb: Brother was meant to start on it this week, not sure has that happened or not. Going to make a spit for it hopefully this week, should make things a bit handier.

I'll probably go with making my own manifold but if you have a link handy by all means post it up for a look.
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Fri Jan 14, 2011 11:27 am

Jozi wrote:but if you have a link handy by all means post it up for a look.
Yes please winkeye
Having proven fit manifolds to buy would probably make life slightly easier :wink:
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hulstijn
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Sun Jan 16, 2011 11:28 pm

rancido64 wrote:
Jozi wrote:but if you have a link handy by all means post it up for a look.
Yes please winkeye
Having proven fit manifolds to buy would probably make life slightly easier :wink:
You'll need the so called "longtube" exhaust manifolds.

Mine have just arrived from Germany:

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these won't fit:


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I don't know if its the same with RHD E30's ;)!

I bought mine from Ebay.de then you have to search for "e36 FächerkrÃammer" FächerkrÃammer means exhaust manifold ;)! Mine were only €139, it saves me a lot of welding, and hopefully I'll get better exhaustsound..
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Sun Jan 16, 2011 11:29 pm

As nice as they look you have no chance of getting a steering linkage through there!
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Jozi
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Sun Jan 16, 2011 11:33 pm

That answers that then :( They do look nice. Maybe I should just move back to Holland now, chances are it will happen eventually anyway.

Got the bush filler btw Dan, thanks!

Small update, spend yesterday making up a spit, nearly done just a few things to sort out before it can bolt to the car.

My brother has had a look around the car and couldn't find anything I hadn't already seen. He reckons there's maybe 3-4 patches needed, we might endup finding some more once it's on the spit and I get a good look my self. Pretty happy with the lack of rust though and it was a free shell as well :cool:
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Mon Jan 17, 2011 12:06 am

Good work jozi mate :D, shame about those manifolds! They do look nice but like dan said, you would have to loose the steering linkage, which aint exactly practical 8O lol.

Nice work though pal 8)
A 2 door e30 with 8 cylinders, what could be better winkeye :D
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Jozi
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Sun Jan 23, 2011 11:09 am

Bit of work done yesterday, we got the spit rolling and the car onto it. Had a quick look around the car with the cam, don't look bad at all :dance: Now to learn to weld :o

2 tourings keeping each other company

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It's only bent because of how we lifted the whole car with the engine hoist resting on the box section
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Bit of bent metal here from when we were putting the shell on the trailer using a tractor, sill got a slight ding as well
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Bit of surface rust here
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Both rear pockets were full of water when we got the shell home, sorted them drilling a small hole :rolleyes:
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Can the holes under the seat be plated up or better to get the caps or what ever they are called for them?

Prob should have posted this in the photo section as will be another while before engine work starts :(
Last edited by Jozi on Sat Apr 09, 2011 8:03 pm, edited 1 time in total.
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Sun Jan 23, 2011 2:06 pm

Nice to see you're making more progress than me anyway mate :D
Still awaiting delivery of my engine, however Ben's promised me some free m52 tubular manifolds because i've had to wait so long for the engine.
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Jozi
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Thu Feb 03, 2011 10:12 pm

Small update from last weekend, not much done because of my brother leaving for Oz.

Got both jacking points cut out and welded up with some fresher looking steel.
Started removing the heatshield to get a look at some rust on the floor, cut a nice hole and started welding it up then it got dark - have to finish this this weekend :o

Few pics of the floor
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We had a look at the rear arch, prob the worst job to take car of, unsure of how to tackle it. Looks like the rust might have started eating at the outer arch

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If anyone know of a tutorial or wants to lend and hand or advice :thumb:

Could a mod move this to the proper section, for now there won't be any m52 related stuff going on :(
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Jozi
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Sat Apr 09, 2011 8:14 pm

[could a mod move this to the photo gallerym, as there's very little m52 action going on here for now]

I haven't updated this thread for quite some time, haven't really done a whole pile since the last update.

Very little work was done in February:

The hole that was made in the floor all welded up and ground smooth-ish
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Introduced my front subframe to the wirewheel on the angle grinder, and evening of that and it was all bare metal. Have welded in subframe mount reinforcement plates, primed it 2x and 1 coat of hammerite smooth black. The front ARB got the same paint treatment, will add a few more coats once the body work is done and do the same with the rear beam and ARB.
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This was like this when I got the shell
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Rear jacking point got a coat of primer after meeting the angle grinder with wirewheel, might cut the jacking point out it tends to go a bit rotten there.
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I had a picture of the drivers side rear cill, opposite as above, but I can't find it, here it is anyway with the rust cut out :eek:
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And 1 plate welded up
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Ran out of light but got the plate on the inside of the arch nearly fully welded in, plug welds let go on me :mad:
Anyone know should I have recreated the step or change of dept of the seam, only realised after having it all welded up there's a step. Will also drill the hole for the rear beam mounting once I fit the beam.

I patched up 2 other area's I'll get pics of them finish, no before pics of it though.

Thats all for now, will finish the above off tomorrow and then no more work on the car till Sat/Sun.

21/03/2011
After a week+ of doing nothing I got the 2 fuel tank mounts cut out plated up and one new and the old bracket welded back on and seamsealed. Cut 2 other holes where the rear break lines go, will have to make up a new bracket or re-use the old ones tomorrow. Then it's onto the area where the handbrake cable is welded on, nice wee hole there as well.

23/03/2011
It's been 3 weeks now since any sort of real progress :o here's a few pics of the last two days worth of work. Had to make 1 new bracket to hold the tank, re-used the other and also the 2 brackets for the brake lines.

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Up next
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24/03/2011
Started taking all the area's I touched up, removed rust or plated up back to bare metal yesterday with the intention of getting primer on it today. First up though, a few new studs.

Screws I ended up using (found them in the shed after I got back from buying some that were to small)
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In the vice

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Flatten tip with the grinder
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Flip it over
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Cut the head of
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And here's a few of them
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Rotten stud
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Cut of and area flattened a bit with the grinder
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And one of the studs welded on
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Here's where I'm at now, lots of bare metal :(
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I was going to get sanding at the engine bay and have it primered as well, thinking I'll sand all the bare matal tomorrow and get some primer on it before moving on to the engine bay.

There's a couple of tricky brackets that need to be cleaned up by hand and the bolts holding the bumper mounts on will have to be replaced one it's of the spit.

31/03/2011
I think I got all the cracked underseal removed and all the rust found, finally. Few new holes as well that I will start at this evening, the end looks to be insight! A good clean-up and a sand and I can get some primer and paint on all the area's I cleaned up.

Then engine bay... then interior... then I'm sure...

Haven't taken any pics in the last week or more, it's a bit time consuming and I'm not keen on the cam lying out all exposed.

Took a few pics:

Here's where I'm at now, lots or bare metal all with a coat of kurust on it:
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Soon to be primered and painted

I decided to investigate why the seatbelt points? looked so flakey, 2mins later and not much metal left - another 2 holes :mad:
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A few attempts at making a nice piece of metal later...
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Getting better at the welding as well, got a few good runs of nice weld doing them 2 patches - not quite visible in the above pic. Both patches were also plug welded to the brackets behind them. Plug welds needed a bit of grinding to get them flat, prob could have done a bit more grinding on the other welds but didnt bother as it wont be seen.
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Tried my best to seal the gap between the plate and the bracket with seam sealer. Trapped moisture here was prob the cause of the rot the had developed!

2 new holes, both on the cills at a drain opening, one by the front wing the other where the petrol tank is
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Will get these plated up and then prep for primer, paint and when I get it underseal.

Next up then:
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Getting there, slowly

[04/04/2011[/i]
Some new parts collected at the weekend

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Rubber coupling (doughnut), Propshaft Bearing, Rear Subframe, Trailing Arm bushes, ARB Bushes (front and rear), Drop links (front and rear) and Gearbox Mounts. Eccentric control arm bushes will be carried over from the blue touring (attached to newish arms). No top mounts because I'm hoping to fit coilovers at some stage and had no trouble with them (as far as I could tell).

And I got this delivered just before the weekend
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It's a rivnut tool with some rivnuts which will be used to hold on the brackets for the fuel lines and where ever else I can find a reason to use it :p

Break & fuel lines should be here this weekend as well, my to-get list (and wallet) is getting smaller and smaller (the amount of work to-do isnt though :p)

Brake lines also got delivered, two roles of kunifer pipe.[/i]
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Jozi
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Sat Apr 09, 2011 8:20 pm

06/04/2011
Had a few things to do earlier this morning but I got started on making 2 small rusty holes into two larger holes.

The infected area at the drivers side rear jacking point:
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Resultant hole:
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And this is near the drivers side front wheel arch, close to where the jacking pad used to live. A bit trickier to get at as there's 3 different sheets of metal all joined together and there wasnt much room for the angle grinder
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And the resultant hole after showing it the angle grinder and dremmel
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I've cleaned up the seam and part of the original metal and welded it back in, just 2 plates to make up for it. (Bottom of picture with the nice folds and lip)


Got a 3rd coat of paint on the front subframe and roll bar, I was nearly out of hammerite smooth black so switched over to one with a hammered finish, think it looks better.
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I made up a list of things to do before I can sent it for paint:

Finish underside - Cut and patch 2 holes, prep bare metal for primer, paint and underseal
Remove rear beam - Weld on tabs and prep for primer and paint
Fuel tank - Removed from blue touring, clean up, paint and under seal
Engine bay - Fix 2+ holes, tidy up front panel, prep for primer and paint
Brake and fuel lines
Paint door shuts
Paint boot lid - Take out glass (being done tomorrow), fix rusted area's, rust proof inside and out
Doors - Plate up key hole, rust proof inside, paint around edges and back, clean and fit locks
Bonnet - sand and paint back of bonnet, cavity wax
Cavity wax everywhere - Chasis legs, Sills, roof, doors, boot lid, bonnet, subframes

The order might change but I think thats all that has to be done before I can send it of for paint :(

09/04/2011
Only took 2 days more than I thought it would :o

This hole was probably the hardest patch I had to do so far!
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I cleaned up the steel from the outer sill and welded it back into place where it was. Then started making up the plate that goes from the sill lips into the car, made a balls of it so cut it all out again, making the hole bigger and started over. It now looks way better than the first attempt and as good as it was before rust got hold, if I may say so myself :D

The plate that cause the headache (taken from inside the car)
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Outside after welding
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Inside after welding
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After a bit of tidying and some primer
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inside the car:
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This was the other hole:
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Much less problems with this one:
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I'm kinda proud of the above and glad I went at it a 2nd time, even if it took up a whole day. Drain holes took a few attempts to make but also worked out well.

Aside from the rear arches, engine bay and a few minor things I cant get at because of the spit thats all the holes patched up on the under side :dance:

Thats it for now then. I look to have all parts for the m52 conversion, box of bits came from bmw some time ago and a few other piece have been collected over the past few weeks.

I had a look at the manifolds today, I'll have to see can I sort them out before the shell is ready for paint.

I'm going to try and get everything sorted to the underside of the car so that when it's back from the paint shop I have as little as possible to be fitted under the car and I can get working on the inside and engine conversion.

Anyone know how to m52 viscous come of? It spins freely as it is now.
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Sat Apr 09, 2011 8:40 pm

Solid effort mate
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Sat Apr 09, 2011 8:57 pm

cracking work buddy.
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Jozi
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Sat Apr 09, 2011 9:01 pm

Thanks lads, long way to go yet and want it ready for our big meet in June, going to be very tight!
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Sat Apr 09, 2011 10:24 pm

This June? :mad:
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Jozi
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Sun Apr 10, 2011 2:14 am

E30BeemerLad wrote:This June? :mad:
That was the plan, at this stage I'm not so sure :( I'm going to keep at it though and see how close I can get to that date.
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Sun Apr 10, 2011 7:44 am

Nice one mate,
Enjoying reading about your progress,
:D
Gone, but not forgotten !!
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Jozi
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Thu Apr 14, 2011 8:57 pm

This came as a bit of a bummer:

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Rear sunroof drain and it's rusting from inside the drain. Not sure what to do with it, might get cutting on the blue touring :eek:

A side from that, got the rear beam out of the blue touring, should have it fully dismantelled over the weekend and start cleaning up the trailing arms.

I cleaned up a spare beam (Thanks Dave) and welded on camber/toe tabs and got one coat of primer on it earlier.

Little else to update bodywork wise, getting a sunroof panel and cavity wax tomorrow, fuel lines and brake line fittings arrived to day, have everything bar some clips to get the underside finished.

Loom, engine bay or arches up next :D
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Jozi
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Sat Apr 16, 2011 10:19 pm

Got a little bit done today.

Attacked passenger side rear inner arch with the angle grinder

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New inner arch? (or cut the inner arch out of the blue touring)

Got the whole loom stripped out
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Old touring where she is now
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Have started painting a spare beam, need to get the halfshafts of this one and get painting them and trailing arms
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Latest bit of rust, nothing to bad:
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Also found a bit starting under the rubber for the loom on the firewall.

Bit low on motivation today to get anything done.

Did a 200mile round trip yest to get cavity wax on my way to picking up a sunroof panel (tiny bit of rust on 1 bracket) and dropping some parts of to Scruffy.
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Jozi
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Thu Apr 21, 2011 9:38 pm

After about a week and a half of procrastinating I finally got a little bit of work done today

Started patching the drivers side rear arch, of which I have no pics, not my best welding or attempt at a repair! I have to patches right on the lip to make up next and weld them in then tackle a bit of surface rust and eventually get rid of the under seal.

I also put a second coat of primer on the rear beam and after a good sanding with some 600grit paper I painted a 4th and final coat on the ARB and front subframe
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Thats all really...
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Jozi
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Tue Apr 26, 2011 12:50 am

I did a little work on her towards the weekend, few holes on the drivers side inner arch patched up
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Wasn't sure how to deal with the 2 parches along the inner lip of the arches. Will prob cut the lip of (and possibly weld it back in after), and tack the patch in behind it without having it folded up. At the top of the arch I'll prob cut the lip back leaving only a few mill of it and rolling or folding it up tight against the back of the outer lip.

I cut a hole in the drivers side rear pocket, small enough, made up my paches and started poking a little more and cutting a bigger hole. Bit of a job patching this one up, I didn't bother making a patch to do the whole lot instead I used the patches I made earlier and a new bigger one. Turned out alright I think.

First patch, only realised I forgot a little triangle after making up the patch :rolleyes:
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Same again only tidied up a little with the angle grinder
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And the other patch making up the rear valance after a bit of a tidying.
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Maybe get starting on the two patches i left in the inner arch tomorrow. Lots of surface rust to the back of the rear valance thats not easy to get at cause of the spare wheel well to fix as well.
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Jozi
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Location: Dublin, Ireland

Sat Apr 30, 2011 10:07 pm

Spent some time yesterday making up a patch for this:
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With these two
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Had to go and change the welding gas this morning, the argon co2 gas didn't weld to well. Got these two patches welded up:

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A little hard to see cause the sky was so bright behind the arches.

Next up the other arch, I was dreading this one at the start and left it for last :D here's what it looked like before 3pm today
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Angle grinder with wirewheel to find where the two parts of the wheelhousing are joined
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And about and hour and a half later we got a big pile of this
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Taken from here
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And here's is what will go back in
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I haven't inspected the outer arch yet but it looks like it might have escaped rusting. Hopefully get it in by the end of the weekend!

Dad spend awhile today splitting the cv boots so I can clean up the half shafts and give them new boots and oil before going back on the car.
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Jozi
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Location: Dublin, Ireland

Thu May 26, 2011 12:59 am

Just to update, no work has been under taken since my last post :thumb:




















Well... the shell hasn't been touched since removing the inner wheel housing some 3+ weeks ago. I looked at it a few times and fixed the cover a couple times, removed the rear glass though.

I've ocasionally found some motivation and now have the following in paint or primer
Front subframe - finished
Front wishbones - in primer
Front ARB - painted but was dropped and a small patch is being re-painted as I do the following
Prop shaft - ready for paint
Rear subframe - 1 more coat of paint to do
Rear trailing arms - ready for paint
Disc backing plates - all 4 ready to be painted
CV joint - dismantled and clean as good as I could and all dust covers and hubs painted, ready for re-asembly with new boots, clips and grease
Half shafts - ready for paint
Front callipers and carriers - nearly ready for primer
Rear callipers and carriers - waiting for 1 calliper and will clean the carriers tomorrow and paint

Next I'll be sorting through the varios shadow line door trims I have and getting them painted up. I'm going to try repair one of the dodgy doors by cutting a repair section from a scrap door I have. Ive some other stuff I can't think of right now to do so everything is ready for paint and I finish of the last few remaining things on the shell. Sounds like nothing but there's shit loads of smaller jobs to do like under seal, brake/fuel lines, rust proofing the shell, painting inside and the whole engine bay....
Baz666
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Thu May 26, 2011 4:11 am

Jozi dude looks like you have your work cut out :mad:

keep it up dude 8)
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E46 328ci, sport bumpers, 19" style 95`s
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