'87 Black with a hint of rot - Front end Re-Build

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Mk4_Briggs
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Mon Nov 03, 2014 10:28 pm

I had always wanted an E30, but always thought I would wait until I had finished university and had the money to buy a good one and also the money to look after one properly too.

However, in 2011 I spotted a good one (or so I thought so) up for sale with 80k on the clock for £1800. So I bought it. I figured that it if I waited any longer to buy one that they would become too expensive to find a good one and I was in a situation at the time where I didn't need to drive everyday so it wouldn't get abused too much either.

After buying the car I did a bit of work on it cleaning a few areas up and putting the alloys on it, but other than that I just washed it, repaired it when needed and most of all enjoyed it.

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I enjoyed it so much, that when I had to enter the real world and start working and commuting I just couldn't bring myself to sell it. Seeing as it had just clicked over 100k and started to get a bit shabby from spending the last three years outside I decided the best thing to do was to buy another car to use as the daily driver and then to start to slowly improve the condition of the old girl.

I knew the front end needed a bit of attention as the front valance had started to rot on the corners and there was some rot starting on the front wings behind the bumper. As well as that, one of the brake disc shields had rotted through so I figured I may as well repair the rust on the panels and strip the suspension to replace the tatty bits and give everything else a good clean.

This soon turned into a lot bigger job than I first thought.

So the first job was to remove the front bumper to see what the little bit of rot on the wings was really like.

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At this point I found a hole, and from this point on it all got a lot more serious.

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Still not too phased I thought it was best to remove the wings and have a good look at everything hiding away. Easier said than done when it turned out that the front wings had been welded on!! It appears that at some point the area just behind the front wheels had been repaired, but rather than remove the wings to repair them the job had been done in situ resulting in them being welded to the car.

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With the bodywork removed the time came to give everything a good stabbing with the screw driver to see to what extent the rot had set in. I was not too happy.

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No going back now then.

Because I don't want to become one of those people who begins a project but then never gets around to finishing it, I decided that I will repair/restore the front end of the car ready for driving it again in the Spring. And then next winter I may do the rear end etc. A rolling restoration if you like. So a plan was made and I cracked on with stripping the front end down further.

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After its stripping it was off to the bodyshop for its welding to be done.

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This pretty much brings me up to date as to where things are at the moment. The car is due back in 2/3 weeks, but in the mean time I have few parts to begin cleaning up and I need to plan all of the next stages to make sure I get this thing back on the road in the spring!

Dan
jimbom30cab
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Mon Nov 03, 2014 10:33 pm

Great thread, nice work. Car looks great also.

It's diss-heartening when you find rust holes but it's standard procedure for e30s and you soon get used to it !!! Actually your's isn't that bad.

Looking forward to seeing the re-build continue, cheers.
polsta
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Mon Nov 03, 2014 11:24 pm

Good work , threads like this with those brave enough to teskky look , go to show that rust is skesys there to be found , "rust free" is too easily banded about by owners these days by people who have never properly looked
Mk4_Briggs
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Sat Nov 08, 2014 3:43 pm

So whilst the car is away I'm working on some of the parts that are removed from the car. Today I set about removing the SI batteries from the instrument cluster as as far as I was away they had gone. My reasons for believing that they had gone was because my fuel gauge would stop working from time to time (for nearly a year at one point) my rev counter would sometimes choose to display something totally different to what the engine was actually doing and the inspection light wouldn't go off when it had been reset.

For peoples reference, here are my clocks front and back.
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and once opened up
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The batteries are located on the circuit board at the bottom of the cluster housing (at the bottom of the photo above).

After removing the board from the housing I checked the voltage of the batteries and got 2.99V which would suggest to me that they are fine (3V batteries) and not the source of the problem. I am assuming that the number on the battery (photo below) indicate that these batteries were manufactured in December 1992. Can anyone confirm that this is a manufacture date?
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So the batteries appear (although I'm no expert at electronics by a long way) to be fine. However there seems to be some kind of leakage on the board which has spread between a number of components.
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Has anyone seen anything like this before? I am starting to think that this leak was the actual cause of my problems and not the batteries. Either way, from what I have read it seems that the best/only solution is to get a full new board. Anyone know of any sources?

Dan
appletree
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Sat Nov 08, 2014 5:55 pm

Could you not scrape away the dusty stuff and buy a new one of the compents and solder it back on? Maybe worth a try??
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Brianmoooore
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Sat Nov 08, 2014 10:35 pm

The 'leakage' on the board looks to me like it may be a kind of adhesive used on circuit boards, which is known to cause problems when it becomes partly conductive.
The numbers on the batteries are the manufacturing date, and the bright yellow arrow sticker is pointing at a jumper link 'switch' for the batteries. This indicates that your cluster has had a replacement board at some time, as the 'switch' was not fitted to OE fitted boards, on the assumption that they wouldn't be sitting around unused for long.
The batteries on your board are not rechargeable, and once exhausted, need to be replaced. This type of battery doesn't deteriorate over time though, and current is only drawn from them when the board is disconnected from the main car battery. New batteries should be able to power the board for around five or six years in total, so unless your cluster has been out of a car or in a car with no battery for long periods of time, without the jumper link removed, they should be OK.
There's something odd about your board though, that I've never seen before - the batteries and a few bits, including a green LED, appear to be mounted on a daughter board. All the SI boards I've seen, whether of the earlier type with NiCd rechargeable batteries, or the later type with Lithium batteries, have had a single circuit board, with just the LED SI lights on a small daughter board at right angles.
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l16ydl
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Mon Nov 10, 2014 12:06 am

You can always rely on Brain. :D
Mk4_Briggs
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Mon Nov 10, 2014 8:10 pm

Thanks for that Brian. The 'leakage' stuff is rock hard doesn't feel as though it will be coming off any time soon. Im getting the feeling that the most sensible decision might be to get a totally new board if i can find one available.
e30Passion
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Tue Nov 11, 2014 2:20 pm

A new one will problably cost a small fortune:
http://www.ebay.de/itm/Original-Leiterp ... 3a99890548

Think you better go for a good second hand:
http://www.ebay.co.uk/sch/i.html?_odkw= ... d&_sacat=0

The daughter board i believe are the later type but not sure.
Mk4_Briggs
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Fri Nov 21, 2014 7:39 pm

Looks like a second hand board will be the answer. It's a bit annoying when there is nothing really wrong other than some dials being wrong but its best to be sorted.

The car is still away at the bodyshop and is due back in a week, I cant wait to see it without any holes in it! In the mean time I have bought a few bits ready for when the car comes back.
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First lot of parts includes new engine mounts, ARB Drop Links, ARB Bushes, Cam Belt, Tensioner, Aux Belt and Power steering belt. There are quite a few more things to buy but I haven't got around to that yet.

The power steering belt was bought in preparation for getting the full PAS system which I collected last weekend and have spent some of this week cleaning up.
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I have the rack and the header tank cleaned up too but don't have any photos. Hopefully I will get the next batch of parts ordered in this week so that I have nearly everything ready for when the car returns.
Mk4_Briggs
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Mon Dec 01, 2014 10:26 pm

She's back!
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The battery tray is a bit plain bit its good strong metal at least. Seems a shame to scratch it up with a battery.
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jimbom30cab
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Mon Dec 01, 2014 10:58 pm

Wow, very shiny !!

Looking good now. You may want to see why the paint has cracked on that front inner wing and ensure it's fully protected before it goes back on the road.

This is turning into a epic re-build.

Keep up the good work

:cool:
Speedtouch
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Mon Dec 01, 2014 11:43 pm

You could always use a mat of some sort to protect the battery tray. :wink:
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Mk4_Briggs
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Wed May 06, 2015 7:57 pm

So I didn't do a very good job of keeping this up to date, but thankfully I can report good news as the car is now back together and complete :D

After the car was returned from the bodyshop it was time to strip the suspension and subframe for a refurb. It was all in a pretty sorry state
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All painted up/replaced where needed
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Powder coated subframe and power steering rack fitted
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Whilst all of the running gear was off I cleaned up and re-undersealed the inner arch before refitting the suspension and subframe
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Next up it was just a case of putting all the rest of it back together, including nice new arch liners and new panels
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And so, after 7 months, I had it all rebuilt and ready for the bodyshop
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The day after getting the car back from the bodyshop I managed to get the car out to its first show in a long time. Was good to see it shining in the sunshine once again

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Just a few post rebuild issues to iron out now but other than that its all finished :D
Mitchen
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Wed May 06, 2015 9:07 pm

Great thread! That front end rebuild is something I need to do at some stage. Lovely looking car.
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Fal_325i
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Fri May 08, 2015 12:36 pm

Excellent work there, looking forward to the rear end rebuild. :D
jimbom30cab
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Fri May 08, 2015 1:17 pm

Well worth all the effort there, you should be very proud. :)
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