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Discussion Starter #161
All back together now, waiting to get the wheel installed.

All bodywork painted areas were coated in bilthammer cavity wax

I ended up replacing with new the following.

Inner ball joint
Outer ball joint
All associated nuts and bolts
Brake disc backing plate
Wheel bearing
ABS sensor














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Discussion Starter #162
I eventually replaced the bonnet release cable, I now have a bonnet that opens on both sides without having to go in under the wheel arch.



I also had a go at restoring the original wheel bearing.





Now sat in the parts box covered in oil


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Discussion Starter #163
Started on the driver's side restoration, impatience and the need to do something to keep the mind clear. This is what I am faced with.







Having the correct tools and practice had made the dis-assembly of this side easier, but of course not without it's issues one still unresolved, awaiting a grinding cutting disc delivery.

I again had to remove the hub assembly as a complete unit. Do we all just love rust........







A pile of rusty parts to sort out or replace, parts and paint ordering has commenced again.



The outer ball joint could not be removed, rounded nut and lots of rust, the pickle fork could not remove it, eventually after cutting the nut off a very large hammer hit many times released it, hit away from you and in the direction of nothing of value, it took down a number of my Lin bins on the walls.

Currently soaking the drive shaft and brake line bracket in deox c gel.







This is currently being very stubborn, access is limited as I am not removing the drive shaft. The bolt rounded and even my Irwin bolt extractors are also failing, next step is to cut the ball joint bracket off and see how that goes.




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Discussion Starter #166
The difficultly in removing the inner ball joint continued and eventually was removed with 1500mm breaker bar (old curtain pole), not before I slipped with a pry bar and split the inner CV Rubber boot. So I had to remove the driveshaft which I was not planning to do which created much greater access to the seized bolt.

£42 later from BMW I had a new rubber boot and clips. Whilst out I thought I would refurbish the drive shaft.

Initial plan was to improve insitu, deox C gel cleaned it up.





Once off the car I could strip it down, circlip removed, tripod bearing gently tapped off, remaining rubber boot removed, 16 year old grease cleaned away, lots of emery cloth on the shaft followed by deox c gel to enable painting and re-assembly with new parts.








All parts are now refurbished and ready to be reinstalled, I just need to do some scrubbing of the wheel arch and a little bit of surface rust removal before painting and then I get get it all back together and off the axle stands.



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Discussion Starter #167
All the surface rust which was minimal was ground back to bare metal, treated with deox-c, zinc primed, seam sealed, stone chipped and then a top coat, all for preservation purposes. It was the healthiest corner of the car with minimal surface rust mainly on the spot welds. I then applied where needed some clear cavity wax.









With a new inner ball joint installed


The tie rod end was rather difficult to remove and took about 5 minutes of constant heat from a butane burner (16 years of activity).

Eventually the driver's side is now all re-assembled

Ending up replacing the following with new

Inner ball joint
Outer ball joint
Track rod end
Wheel bearing
Inner cv rubber boot
Brake disc plate
ABS sensor
Every bolt

During the re-assembly process





All back together






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Oh snap! What the underside like?
Was yours crusty on the passenger side round the threaded studs that hold the battery cable in place?
 

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Discussion Starter #169 (Edited)
Oh snap! What the underside like?
Was yours crusty on the passenger side round the threaded studs that hold the battery cable in place?
The whole rear end was in a bit of a state especially around the fuel tank, it was all surface rust though that could be removed but it took months of using a flap disc on a grinder, belt sander and multiple grinding stones in a Dremel.


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Discussion Starter #170
Life's been busy this year I've been moving things along slowly.

The front tyres were getting towards the legal limit, and had been like that for some time with no change due to the lack of mileage. Two new Toyo T1R Proxies were installed. Sometime ago I also foolishly damaged one of my wheels on a kerb, I bought a replacement at the time and the damaged one sat covered up in my workshop area, the wheel specialist did a good job repairing it and I now have a perfect spare wheel.



A number of years ago some nob head in a car park damaged my driver's side Rear arches, I did a quick repair job and forgot about them, although not perfect I have now repainted them both.



Whilst I had the rattle cans out I also repainted the front passenger side arch as I had chipped the paint during my inner arch restoration "slipping on a seized nut with a breaker bar"



Whilst installing the newly painted item I noticed that the a panel arch was not seated correctly one of the moulded clip holders was broken, I made a template from thin plywood, and using the plastic top of a CD storage case I made a replacement and bonded onto the arch left it for 48 hours and then reinstalled.



I was lucky enough to purchase some time ago a v monitor for a very reasonable price which I have now installed in the useless space underneath the steering wheel.

Although currently on the floor due to ongoing work.

I recently purchased at a remarkably low priced GTT oil catch can which I bought as a spare, I have now completely refurbished it.



........................in a malt vinegar dip




Whilst working on the interior I damaged beyond repair my first ever addition to my car an iPod cable which got caught in a seat runner.



Getting a replacement was a little more difficult than I first imagined although gave me a chance to take apart something I haven't before.




To help to complete my interior I have had the cup holder moulded section carbon hydro dipped (by Vital Hydro graphics in Staffordshire)




Whilst taken apart, new anti squeak tape was installed every where.

Current carbon parts waiting to go back on the car (waiting for the blue plastic nuts to arrive before I put it all back together).



This part is currently being dipped.



I have the seat backs off ready to be sent away to be carbon dipped.




Cold air intake......simple monitor installled???????



The following items I hope will be corrected over the next 12 months.

The minor surface rust on the floor pan will be removed on the underside and protected with zinc primer, stone chip and then top coat.

I hope to be able to attempt to remove the front sub frame and have it shot blasted, treated with bilthammer rust removal and convertor, then zinc primed and painted with Por15, with all new fixings installed.

I have a new fuel filter to install

Currently waiting for delivery of a matching Recaro rear seat bench which I have just purchased off eBay.

The current mileage which is likely to remain relatively unchanged over the next 12 months.





Last item I replaced the tatty build date sticker.....it's starting to age.




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Discussion Starter #171
I got the interior all back together













I managed to pick up eventually a two tone Recaro rear bench for a very cheap price, cheap for a reason absolutely filthy, damaged and stinking of smoke.









Scrubbed clean, leather repaired, recoloured and then protected.









Old v New



Installed VI Monitor



Installed Carbon A pillars, not perfect, but the first time I have attempted something like this.





Triple R Composites front splitter, test fitted, painted and then installed














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Looking great
I would get rid of the chrome interior rings tho, kinda distracts from the carbon. Matte or Satin black would look swell

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Discussion Starter #174 (Edited)
I replaced the fuel filter, you have have all seen a filthy one of them, I pulled on it too hard and the level detection fell off in the tank, that was retrieved and then repaired.

I then removed the whole interior from the rear to correct a rust spot and rusty seat brackets, found out why I had a squeaky rear passenger panel as all the retaining clips were missing, new ones were installed.

I wrapped all the cabling in cloth tape whilst in there and sorted out one of the most annoying things for me on the very early models, no remote boot release cable. I purchased a second hand one and got that installed, for a car that does very limited Mileage I always disconnect the battery.







Not to bothered about colour matching, the rust was there as the rubber grommet was missing.









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Discussion Starter #175
Completed the interior carbon dipped parts at the front.

Dash side panels (before and after)






Steering wheel, the centre item is a real carbon cover from RSi.




Rear bench in the car



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Discussion Starter #176 (Edited)
The final part of the underbody restoration has started.

I started by taking small parts off to build up courage.

Power steering pump fan (before & after)






Lower engine mount (before & after)






I then started removing all the bolts and cleaning them up and deliberated cleaning the subframe up insitu, then I did this today, which brings me up to date I think.








The anti roll bar needed fire to loosen the bolts.





The subframe will be shot blasted, rust prevention treated, zinc primed and then painted, and I will probably end up wasting more more money on other parts once I start taking it apart.


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Discussion Starter #178 (Edited)
About ready to now start re-assembling everything. All rusted items have been taken back to bare metal, treated with Bilthammer products and then painted with zinc primer and then Por15.

The underbody which had very minor surface rust has been ground back to bare metal, zinc primed, seam sealed, stone chipped and the top coat.

In pictures - Rust




Out of Rust






Rust killing



Painted









Powder coated ARB



New grease on the steering



Underbody painting and cavity wax






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Discussion Starter #180 (Edited)
Then got on with some routine maintenance, replaced the thermostat and gave the MAP sensors a clean, although had to get some new m4 bolts to replace the original rotten items.










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