Bognor Lean-to Project

[Mazza]

Another day....and a bit more cleaning....
One scruffy looking diff....

Two hours of rust flying everywhere later...

Sitting draining the last of the oil out, and with the rust treatment drying.....tomorrow it will get a coat of high temp black paint.

Then......I had a visitor......
Hole..

Bigger hole.......

No Hole...

And the small holes up by the shock mount also sorted..
By firstly cutting it all out......made an insert piece....

And all solid again....

Red oxided , then some paste was put on to fill the seam. Hence it went pink !!!! I could repaint the car to match
( it will be blown over with a rattle can later, when I get round to finishing the underneath)

The guy who did the welding was really good and definitely will go on my speed dial list Thanks to Mark,( @Althulas) for finding him on FB for me.

I sat ordering loads of parts on Sunday ( with Guidance and supplier info from @Lee ) and parts have already started to arrive.....
Back Plates turned up this morning at 7.10am with Parcelforce.......thats too early !!!!
Over the next few days should be getting sills, beam bushes, brake hoses. Front wishbones and bush kit,
Confirmation received with tracking number to say that the trailing arm is on its way from California.

Loads more bits to sort.....currently making lists to send to BMW, ECP, GSF and Andy (spurs) .
I would have used Autodoc but it appears that their service is not as good as it was, so will give them a miss this time.

Might as well get everything now.....it will only go up in price if I leave it

Oh well ......back to more cleaning and painting

 

[andyglym]

Another day....and a bit more cleaning....
One scruffy looking diff....
View attachment 180027

Two hours of rust flying everywhere later...
View attachment 180025

Sitting draining the last of the oil out, and with the rust treatment drying.....tomorrow it will get a coat of high temp black paint.

Then......I had a visitor......
Hole..
View attachment 180029

Bigger hole.......
View attachment 180055

No Hole...
View attachment 180057

And the small holes up by the shock mount also sorted..
By firstly cutting it all out......made an insert piece....
View attachment 180077

And all solid again....
View attachment 180059

Red oxided , then some paste was put on to fill the seam. Hence it went pink !!!! I could repaint the car to match
( it will be blown over with a rattle can later, when I get round to finishing the underneath)

The guy who did the welding was really good and definitely will go on my speed dial list Thanks to Mark,( @Althulas) for finding him on FB for me.

I sat ordering loads of parts on Sunday ( with Guidance and supplier info from @Lee ) and parts have already started to arrive.....
Back Plates turned up this morning at 7.10am with Parcelforce.......thats too early !!!!
Over the next few days should be getting sills, beam bushes, brake hoses. Front wishbones and bush kit,
Confirmation received with tracking number to say that the trailing arm is on its way from California.

Loads more bits to sort.....currently making lists to send to BMW, ECP, GSF and Andy (spurs) .
I would have used Autodoc but it appears that their service is not as good as it was, so will give them a miss this time.

Might as well get everything now.....it will only go up in price if I leave it

Oh well ......back to more cleaning and painting

You love this cleaning game Malc

 

[t-tony]

A very productive day you've had mate Wish I had a £ for every hole like those I've welded up in the past. Amazing how much better they look when plated and painted.

Tony.

 

[gookah]

Look up engineering bolt marking charts, very interesting reading that covers Yield Strength and Proof Load etc.

Ahhh, Youngs' modulus,

I read a similar book
It was all about the fixings that hold ships together.......... riveting.

 

[Martin Sullivan]

This is all looking really good! Very impressed with the commitment

 

[Mazza]

Seven and half hours in the garage today.....cleaning and painting..

But before that there was a promotion in the Bognor Lean-to........I promoted myself to supervisor, and awarded myself the red overall. I have noticed that Trev ( @Oldguysrule ) has one at ZSHQ, So obviously Trev must be in charge.

Didn't fancy getting underneath first thing in the morning so as the battery had been removed for the welding , decided to clean up that first.
Not too bad, but went over with a wire brush, and painted on some rust treatment.

When it was dry, the red oxide.....

Then a quick overspray with a zinc antirust primer, and also went over the welded repair

So a good start, then came the hours of crap, acid , and paint dropping on me

It was just a case of getting on with it ......to the sounds of sixties and seventies cds ringing out

The brake lines are crap, so I cut off the the end joint that was seized, and bent them out the way.....sort them out later. Also moved all the wiring out of harms way

Treated

Then red oxide....

It was a bit overkill on my part, but don't want to be doing this again

Went over the repair with some red oxide

And while waiting for things to dry....
Painted the diff.

So all in all a long but rewarding day.....so allowed myself beer ........’s

And the new parts are arriving and mounting up.....

Sills, front-end wishbone kit, ( and haven't even started on that end yet) brake hoses, rear back plates and beam bushes.
Still loads more to come yet. .and loads to order......

I wish I had never gone out in Lees’ car now ........


As for long term .....I have decided to make this an ‘extended family’ car. Hence why Everything is going to be done. Once finished it will be insured for anyone in the extended family over thirty, to use as a weekender, or holiday car. Give them a taste of Z3 motoring!!!!!

 

[andyglym]

Seven and half hours in the garage today.....cleaning and painting..

But before that there was a promotion in the Bognor Lean-to........I promoted myself to supervisor, and awarded myself the red overall. I have noticed that Trev ( @Oldguysrule ) has one at ZSHQ, So obviously Trev must be in charge.

Didn't fancy getting underneath first thing in the morning so as the battery had been removed for the welding , decided to clean up that first.
Not too bad, but went over with a wire brush, and painted on some rust treatment.
View attachment 180207


When it was dry, the red oxide.....
View attachment 180209

Then a quick overspray with a zinc antirust primer, and also went over the welded repair

View attachment 180211

So a good start, then came the hours of crap, acid , and paint dropping on me

It was just a case of getting on with it ......to the sounds of sixties and seventies cds ringing out

The brake lines are crap, so I cut off the the end joint that was seized, and bent them out the way.....sort them out later. Also moved all the wiring out of harms way

View attachment 180213
Treated
View attachment 180215


Then red oxide....
View attachment 180219

It was a bit overkill on my part, but don't want to be doing this again
View attachment 180223

View attachment 180221
Went over the repair with some red oxide
View attachment 180217

And while waiting for things to dry....
Painted the diff.

View attachment 180225

So all in all a long but rewarding day.....so allowed myself beer ........’s
View attachment 180229

And the new parts are arriving and mounting up.....
View attachment 180231

Sills, front-end wishbone kit, ( and haven't even started on that end yet) brake hoses, rear back plates and beam bushes.
Still loads more to come yet. .and loads to order......

I wish I had never gone out in Lees’ car now ........


As for long term .....I have decided to make this an ‘extended family’ car. Hence why Everything is going to be done. Once finished it will be insured for anyone in the extended family over thirty, to use as a weekender, or holiday car. Give them a taste of Z3 motoring!!!!!

Superb stuff Malc and great Red Arrows overalls ..... Red 1

 

[ViperKen]

Well deserved beer

 

[Althulas]

Making some headway there Malc, nothing wrong with a bit of overkill prep

 

[Synclare]

.

 

[Ian&Sue]

Seven and half hours in the garage today.....cleaning and painting..

But before that there was a promotion in the Bognor Lean-to........I promoted myself to supervisor, and awarded myself the red overall. I have noticed that Trev ( @Oldguysrule ) has one at ZSHQ, So obviously Trev must be in charge.

Didn't fancy getting underneath first thing in the morning so as the battery had been removed for the welding , decided to clean up that first.
Not too bad, but went over with a wire brush, and painted on some rust treatment.
View attachment 180207


When it was dry, the red oxide.....
View attachment 180209

Then a quick overspray with a zinc antirust primer, and also went over the welded repair

View attachment 180211

So a good start, then came the hours of crap, acid , and paint dropping on me

It was just a case of getting on with it ......to the sounds of sixties and seventies cds ringing out

The brake lines are crap, so I cut off the the end joint that was seized, and bent them out the way.....sort them out later. Also moved all the wiring out of harms way

View attachment 180213
Treated
View attachment 180215


Then red oxide....
View attachment 180219

It was a bit overkill on my part, but don't want to be doing this again
View attachment 180223

View attachment 180221
Went over the repair with some red oxide
View attachment 180217

And while waiting for things to dry....
Painted the diff.

View attachment 180225

So all in all a long but rewarding day.....so allowed myself beer ........’s
View attachment 180229

And the new parts are arriving and mounting up.....
View attachment 180231

Sills, front-end wishbone kit, ( and haven't even started on that end yet) brake hoses, rear back plates and beam bushes.
Still loads more to come yet. .and loads to order......

I wish I had never gone out in Lees’ car now ........


As for long term .....I have decided to make this an ‘extended family’ car. Hence why Everything is going to be done. Once finished it will be insured for anyone in the extended family over thirty, to use as a weekender, or holiday car. Give them a taste of Z3 motoring!!!!!

Great job Mazza. Don't think you can do overkill where rust treatment/prevention is concerned.
Looking cool in the red overalls. They should frighten the car into submission!

Ian.

 

[Mazza]

Not a lot going on today....as in working on it.........but got on with the component sourcing..........

Had a quote from Sopers and my local dealer.......and Sopers got the order.....

So took me about two hours of checking part numbers from the quote and cross checking with RealOem to make sure everything was correct.....and sent off a £500.00 order......and I left off the expensive items for now....!!!
The order just covered the hardware and fixings for the back end but not worth reinstating duff parts.

@Lee sent me a picture of the treated parts that he has had back, and the beam ( sourced from Andy ) and cross brace look really good.
So With the N/S trailing arm from Lee( already powder coated) And the O/S arm which cleared customs this morning and is on its way to me, all the main parts covered.

With the Bearings ordered, Trailing arm bushes ordered and Beam bushes and back plates already arrived, it wont be too long hopefully before I will have all the parts ready to offload to ZSHQ to watch them being assembled
I suppose the coffee and cakes will be on me

Need to sort out the brake lines while I have full access underneath..... ( and they will need to pass @t-tony ‘s discerning eye ) Might use the existing pipe to practice with and try to rebend it to how it should be.


Early afternoon was a run out to the local dealer to pick up 1 bolt and 2 nuts...........essential journey !!

Then home to welcome guests to the ‘ Lean-to ‘ . Alan and Maxine dropped in to have a look at ‘ Project Junk Pile ‘ but I think really the visit was just check on my sanity after buying it.

As they were driving off in their nice Boston Green 6 pot, I’m not sure if Maxine said “I was showing great commitment” or “ that I should be committed” !!!!!!

 

[t-tony]

You'll soon be looking back on it thinking what was all the fuss about Malc., and the kids will be saying where has our inheritence gone ?

Tony.

ps. Have a flick through some of Lee's pictures of cars with the rear susp. removed. You will get a good idea where/how to route the pipes.

 

[Mazza]

Today was mostly painting ....oh goody !!

The final use of the screws of doom was to act as thread protectors while a splodged on the underseal.

There was one thread that needed cleaning out but could not get a tap in to clear it.....

Bit worrying as I can’t remember what fits on to it.
But ground off the side of a bolt and used it to clean out the thread.....worked a treat !!

Then just boring painting....

This will take about 24 hours to dry, but I will leave till Friday and give it a second coat. At some stage I will have to move the axle stands and jacking points and paint all those areas, Probably end up doing one at a time ( for safety reasons !!!)

One thing that got broken while dismantling, was a breather/ vent tube. A bit of tidying up with a sharp knife and some gorilla glue has sorted it . The top slotted part got snapped off when I pulled on the pipe.....didn’t realise there was another clip higher up holding the tube.

And the last thing I did was more for safety reasons.....
The drivers door mirror is held together with tape and a bit on the floppy side....

So I removed the glass mirror in case it got damaged....

And found there is only one screw holding the two parts together.......
But I do have an old silver one that I will strip down and cannibalise to make one good one.
I also took the glass out of the passenger side as well for safe keeping. Both now wrapped up and out of harms way.
And I will probably forget what I’ve done with them when it comes to reassembly..


That was it for today....other than a frantic call to Sopers, to increase the qty’s of two of the bolts I had ordered. I decided I didn't like the look of some of them that I had taken off.

So onwards and Pubwards.....

 

[Althulas]

If you want to match the greenish finish Malc RAL 7002 comes quite close.

 

[t-tony]

Today was mostly painting ....oh goody !!

The final use of the screws of doom was to act as thread protectors while a splodged on the underseal.
View attachment 180881

There was one thread that needed cleaning out but could not get a tap in to clear it.....
View attachment 180883
Bit worrying as I can’t remember what fits on to it.
But ground off the side of a bolt and used it to clean out the thread.....worked a treat !!
View attachment 180885

Then just boring painting....
View attachment 180887
View attachment 180889
View attachment 180891
View attachment 180893
View attachment 180895

This will take about 24 hours to dry, but I will leave till Friday and give it a second coat. At some stage I will have to move the axle stands and jacking points and paint all those areas, Probably end up doing one at a time ( for safety reasons !!!)

One thing that got broken while dismantling, was a breather/ vent tube. A bit of tidying up with a sharp knife and some gorilla glue has sorted it . The top slotted part got snapped off when I pulled on the pipe.....didn’t realise there was another clip higher up holding the tube.
View attachment 180901

And the last thing I did was more for safety reasons.....
The drivers door mirror is held together with tape and a bit on the floppy side....
View attachment 180905

So I removed the glass mirror in case it got damaged....
View attachment 180903

And found there is only one screw holding the two parts together.......
But I do have an old silver one that I will strip down and cannibalise to make one good one.
I also took the glass out of the passenger side as well for safe keeping. Both now wrapped up and out of harms way.
And I will probably forget what I’ve done with them when it comes to reassembly..


That was it for today....other than a frantic call to Sopers, to increase the qty’s of two of the bolts I had ordered. I decided I didn't like the look of some of them that I had taken off.

So onwards and Pubwards.....

Some good progress there Malc.

Tony.

 

[Mazza]

If you want to match the greenish finish Malc RAL 7002 comes quite close.

I wondered about what paint it is ... I dont really want to leave it black.....I was going to use a grey stone chip over the top of the underseal, but I will see about getting some RAL7002

 

[Mazza]

Had an early start today....for more painting and derusting.....


Got a second coat of the black goo underneath and along the sills, then had a go at derusting the hubs and drive shafts ready for painting

@t-tony , nearly finished the brake lines....pretty good eh !!!!!

There might be one bit thats a little off

The two connectors are seized solid....so I just bent everything out the way. I will need to completely start again with these so I will take off the fuel filter cover to see where these pipes go and see if there are any other joins further along towards the front. But a job for another day....

Thats it for today as I have to have my second covid jab in about an hour

 

[t-tony]

Had an early start today....for more painting and derusting.....


Got a second coat of the black goo underneath and along the sills, then had a go at derusting the hubs and drive shafts ready for painting

View attachment 181107

View attachment 181111

View attachment 181109


@t-tony , nearly finished the brake lines....pretty good eh !!!!!
View attachment 181113

There might be one bit thats a little off

The two connectors are seized solid....so I just bent everything out the way. I will need to completely start again with these so I will take off the fuel filter cover to see where these pipes go and see if there are any other joins further along towards the front. But a job for another day....

Thats it for today as I have to have my second covid jab in about an hour

Had our 2nd this morning Malc. You may find the fuel filter could be old, even original.when you get the cover off.

Tony.

 

[Mazza]

I was thinking of changing it anyway.....especially while the fuel tank is out , it makes it a lot easier, and as you say probably original.