E30 M3 Touring project with S62 power

[Andeep]

Great work. What did you use to get rid of all the underseal underneath?

[turk]

Great to see you're still doing this project Dave.
Great work as usual Inspiration for us all to get out in the cold and make our cars unique and more fun

[DavesM3]

Great work. What did you use to get rid of all the underseal underneath?

Wire brush on angle grinder.


Thanks everyone for the encouragement, it's all needed.

[adit]

found another one on google:




there was a thread on here a while ago about the white one in a garage near Bournemouth

(hope you don't mind the free bump Dave )

[bmaniaco]

Im in love

[DavesM3]

Weekly update

Quarter in place for final trimming to size




Lots of awkward bits ahead
Facelift pocket completely different


And here where the m3 skirts meet the arch


More cutting


Cutting the door line


In place




Lots more areas to be filled




More cutting


Door handle recess and a pocket under for your fingers to fit to open handle as not enough.


Pocket formed and welded

[magpie]

skillz !!!!!

[ImysE30]

Quality work

[DavesM3]

Bit more progress

Final cut on door to fit quarter to door




Lots of welding making sure that panel doesn't heat up. Keep moving around and take a break often



Bit of grinding


Blended in well






Bit of primer


Final trimming and cleaning up for wheelwell


Wheelwell in and quarter plug welded to it


Old standard wheelwell for comparison


Looking towards rear

All tacked up


Still a bit of work to be done to match up the pocket


Corner worked out very well



Now to fill some gaps


And here

On the 2 tourings I've seen that have been converted before a filler piece is used between the door and the m3 quarter like this


And on the closing panel the same thing


Get the door gap nice and even


Then loose the plot


To be continued ........

[Phill172]

Fantastic work!

[F17RAK]

Would love to do this to my touring

[Neilios]

Would love to do this to my touring

I would like it more if someone else did it for me!!

Nice job.

[oomz1975]

WOW some proper effort going into this.

[DavesM3]

A bit of an update again

Here is the reason for the wild cutting the last day
A bit more cutting for good measure


Cut a piece from a breaker to move out the door shut


Door closed


Same thing on door


Move out door edge also


Happy with that


Now to move out the sill to line everything up
Drill out spot welds


And cut the rest out


Part I cut from the m3 quarter before




And do some more cutting for a change


The bottom of the door shut is curved in as standard so a good bit of hammering is required to get it to Match the shape of the m3 quarter
Not perfect but it's fairly close. Can build it up with some weld after


Another piece of the puzzle


Coming together


Due to straightening the shut edge the corner piece was shaped the wrong way
So cut again


Make a piece to fit


And


Shaping up


From the outside

[DavesM3]

Another few bits done

Need to complete this corner



First


Then some new steel cut to fit


Bit of welding


Another bit of door done


Bottom


Few small pieces completed


Bit of new steel cut and shaped to fill in on the door.


Tacked in


Rear quarter welded in completely. Kept its shape extremely well




Time to tackle the rear pocket


Out with my old friend mr angle grinder again


Make up a piece to fill the gap and try and follow the shape of the quarter





All welded up


And ground down


Happy with how it came together

[Neilios]

Exceptional work, very good project. I cannot wait to see it complete.

[dirtee-herbert]

Keep up the amazing fab work! This is an epic project!
Keep it coming!

[G-Bear]

Patched to perfection.. Good work..

[DavesM3]

Thanks for all the great comments. Helps to keep me going.

[Tommek]

Great skillz. Best of luck with it, looking forward to the finished product.

[gooseygander110]

awesome fabricating skills mate.....very brave to !!

[bimmerteam_hu]

Great work so far but an advice for you: You should try to fit the rear bumper because the facelift body is lower than the pre-facelift and M3. You have lowered the side panel and I am afraid that the rear bumper doesn't will cover the lowered part of the car on the sides and bottom rear... Maybe my fear is unfounded but a test-fit costs nothing.

[Rob_farmer]

Stripped all the sealer off the bottom of the car.

Dave, what did you use to get sealer off the bottom?

This one?

[assassin]

This old git is sOOOOO in admiration of your skill and commitment. I wish I was as able as you. Bloody well done sir!

[turk]

Great stuff Dave, Are you shaping the rear to take the pre facelift lights too?

[DavesM3]

The rear bumper fits fine, your correct that the pocket is lower than on an m3 but it won't be seen.


This is the type of wire brush I used


Think I'm getting enough hardship as it is Adem

These little beauties arrived fro the USA along with a nice bill from customs. Greedy b**tards



Very tidy compared to standard lollipop bushes. Will leave a lot more room for routing manifolds



Last piece in the bottom of the door



Welded up



Ground down



Primered





Last bit of the door to be tackled. Not an easy one this with so many angles and pieces



Put in a piece to create door edge



Plenty of banging and cutting to get this fairly right and welded up



Ground down and primered



Looking fairly factory now

[G-Bear]

Another great bit of progress..

Those lollipops are nice, I've seen them on a couple of build treads on here now... pricey too mind.

[Rob_farmer]

Those lollipops are nice

What are they? What`s the benefit of them?

[dirtee-herbert]

Doors are looking very tidy.
I love this thread!!

Found this on ebay. Thought of you pall.

[/url]http://m.ebay.co.uk/itm/271350818535[/url]

He didn't have the trouble of rear door the modify tho and went for a more direct approach haha

[DavesM3]

Few new bits arrived today
Anyone want to hazard a guess
They are genuine bmw
Half of them are nla so I had to get some of them from the US

[M-Sport]

The 2 in top left of pic are for convertibles which mount on front strut turrets, whats the rest?

[S38B38]

What a project !!!

[appletree]

Great work!, but one question how do you intend to prime/ rust proof the areas where you have two sheets sandwiched like the bits you have extended on the rear doors to qurter panels? only ask as I have a sunroof tray to do with similar hard to get to returns.

[DaveyB]

where did you get these panels from?

quarters and wings

cant find any apart from fiberglass reps

[DavesM3]

Great work!, but one question how do you intend to prime/ rust proof the areas where you have two sheets sandwiched like the bits you have extended on the rear doors to qurter panels? only ask as I have a sunroof tray to do with similar hard to get to returns.

I haven't lapped any of the joints, all butt joints so no double skins.
The inside of the sills and other awkward places I'm was planning on using a cavity wax gun to spray lots of zinc rich primer in everywhere