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Go Back   E46Fanatics > E46 BMW > The Showroom

The Showroom
This is the place to show off your BMW to other members of the community. Post pictures and videos of your car and the modifications you have done to it. If you need a picture of something on a coupe, sedan, convertible or touring you will probably find it here!

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Old 09-08-2010, 12:19 PM   #21
tinkwithanr
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i love u.
sooooo h0mo hehe
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good luck. helluva lot of work.
Thanks, it's not that hard just time consuming. Now I just need to find more time lol.
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Old 09-08-2010, 12:35 PM   #22
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subscribed!! This better be good!!
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Old 09-08-2010, 01:29 PM   #23
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So this past weekend I was able to get a big chunk of the rust repair taken care of. There's still a lot of stuff to do, but now I have a feel for what I need to do and more importantly how to do it. This is the first time doing body work and so I'm pretty much learning as I go.


First order of business was to remove all of the rusted out/heavily pitted metal. Once this was done it exposed the frame rail that sits under the floor. Luckily for me it was still very solid, it just has some debris inside.

Driver Frame Rail - Before

Once I cleaned it out, I applied a coat of Weld-Thru primer so I could add some extra support on the inside of the frame with a 1/8" thick sheet metal cut to fit.

The Primer:

Weld-Thru Primer


The Frame Rail freshly primed:

Driver Frame Rail - Primed and Ready


The reason for the primer is that when 2 pieces of metal of butted up against one another they have a tendency to trap moisture, which leads to rust. The best way to prevent that is to paint both pieces before you push them together. But since the insert was being welded in normal paint would be burnt away, so it wouldn't do any good. The Weld-Thru primer is special in doesn't burn away when welding, so it will still protect the metal from rust.

The frame rail with the added metal welded in:

New Patch Welded In

After that I applied a good coat of POR-15 (rust inhibitor). Once that was sealed up I could move on to the rest of the driver's floor. Below you can see where the rust started to run up onto the transmission tunnel ever so slightly. In order to repair this I cut put a template from thick paper and then traced the pattern onto some sheet metal.

The hole:

Driver Floor Before

The metal piece cut from the paper template:

Patch for Driver Tunnel

Once I had the outline cut out I used some body hammers and dollies to get the curve right. Once the shaping was done I tacked it in place until the rest of the floor could be made up. I forgot to take more pictures as I made that piece up, but here's the paper template I made for the other corner of the floor.

Paper Template:

Paper Template

Sheet metal from Template:

Metal cut from template

And here you can see this piece tacked in place:

Tacked in 2

Next in line was the inner front rocker/side of the floor. At first I was going to leave this piece in, but the more I poked at it the more fell out, and so I decided to make up a new patch to cover it up.

The rusty piece:

Old Busted Joint

The sheet metal patch, unbent:

Template of old busted joint

The patch, freshly bent:

New Hotness\

And here is where it got welded in:

Location of old busted joint

Once the sides were patched up I made up the inner floor panels. Here's the left one ready to be tacked in place:

Left Floor Pan



The last thing I worked on this weekend was my crappy stock gas pedal mount. it was rusted and pitted and all around worn out, so I figured I would make a new one.

The old busted joint:

Old Pedal Mount


The new sheet metal piece ready to be cut:

New Metal

The bends matched up pretty good:

Bent up to match

Then I made up some new mounting 'nipples' from some 1/4-20 bolts and acorn nuts. I put the nuts in a drill press and then rounded them off with a grinder until they were the right shape. To hold the bolts in place I welded then through the holes from the back of the mounting plate. Finally I threaded on the rounded acorn nuts down onto the bolts and Voila!


The New Hotness:

New Pedal Mount

And it actually fits!!

It fits!


Last here's a picture of how she sits right now. I still need to grind the welds down and then seal everything up nice and good. I'm hoping to get to that tonight or tomorrow. Then I get to tackle the passenger side....

It has a floor now!

New Floor!
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Old 09-08-2010, 02:06 PM   #24
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sweet - i have considered getting one myself, preferably a round taillight tii
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Old 09-08-2010, 02:18 PM   #25
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sweet - i have considered getting one myself, preferably a round taillight tii
Do it, their great little cars. I'd love to have gotten a tii, but I'd hate to molest a true classic like that. Especially since this will end up on campus with me. I won't loose sleep if this gets a door ding or gets messed with (to a point).

Besides you can't run quad 40mm mikuni's on a tii .....
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Old 09-08-2010, 03:32 PM   #26
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Old 09-08-2010, 03:39 PM   #27
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Old 09-08-2010, 03:50 PM   #28
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Will be following this closely as I too would love to have one someday. Although I don't have any restoration skills I always wanted to trot around town in one of these. I can't believe a 2002 turbo is asking 40k+; with good reason, but still Any plans to change the colour or wheels?
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Old 09-08-2010, 04:15 PM   #29
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Will be following this closely as I too would love to have one someday. Although I don't have any restoration skills I always wanted to trot around town in one of these. I can't believe a 2002 turbo is asking 40k+; with good reason, but still Any plans to change the colour or wheels?
For now it will stay red and I'll stick with the msw's. Eventually I'd love to paint it either the stock turbo white or silver, or maybe phoenix yellow. Next summer I'm planning to do more exterior body work which should include turbo fender flares and front air dam, at which point the wheels might change due to the need for a different offset. All in due time though, I need to get her back on the road first!
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Old 09-09-2010, 09:27 AM   #30
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What are the overall plans anyways?
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Old 09-12-2010, 09:22 AM   #31
tinkwithanr
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What are the overall plans anyways?
For now I'm just fixing all the big rust issues and replacing the important lines (fuel and brake) to make it reliable and safer. Also I'm going to re-seal the inside of the car from the outside. Then down the road (read next summer) I'll make the body more presentable and probably do a complete suspension overhall.


In the meantime, since I don't have enough to work on yet:

Bike Carbs Bought!

They will just need to be re-jetted and then mounted to a custom intake manifold to take the 3.25"-on-center carb spacing to the 4"-on-center intake port spacing. It will also need to transition from the circular outlet of the carb to the more rectangular inlet on the m10.
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Old 09-12-2010, 10:57 AM   #32
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nice work mate! im also glad you are sticking to the period correct mods. that fred flinstone mod had to go poste haste, as it way way too incorrect for its era!
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Old 01-09-2011, 11:43 AM   #33
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Old 01-09-2011, 12:57 PM   #34
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Sorry, progress has definitely been made, but updates to the thread obviously have not. It was on the road reliably from October through the end of November when I had to park it because the defroster fan doesn't work.

I'll make a more detailed post in the near future, but some of the stuff that has been done over the past few months:

- Big Brake upgrade for front (uses old 4 pot volvo calibers that manage to bolt in place)
- e21 rear drum upgrade (250mm drums up from 230mm stockies)
- all new carpet for the whole interior
- new 'silver dollar' gauge cluster waiting to go in (from the earlier '02's)
- Strut bar/battery tray ready to be installed in the trunk
- new period vdo gauges for oil temp, oil pressure, voltage, water temp ready to go in

Pry forgot some other stuff but I'll make a more organized post sometime this week when I can get some pictures.
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Old 01-09-2011, 01:19 PM   #35
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Nice 02 man, these things are fun little cars.
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Old 01-09-2011, 05:19 PM   #36
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Yeah they are. Do you have one?
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Old 01-09-2011, 05:27 PM   #37
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nice find man, you should do something like this one i drove fully restored



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Old 01-09-2011, 05:32 PM   #38
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was it a good driver? I have always lusted over the Turbo
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Old 01-09-2011, 05:34 PM   #39
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Actually those are the flares and front air damn I want to go with, but I don't think I want to paint it white. Especially since I don't wanna go turbo right now I don't wanna seem like I'm trying to make a turbo-clone or anything.

That is very sexy though, where'd you get to see it/drive it?
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Old 01-09-2011, 05:37 PM   #40
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