Get your Tetanus Shots....9/15 Update!

Show off your E28. Read epic threads of other's builds and projects.
Post Reply
Dan84na2T
Posts: 104
Joined: Jan 09, 2008
Location: Philadelphia

Get your Tetanus Shots....9/15 Update!

Post by Dan84na2T »

So this was my 85 535i. It served me well over the past year and a half. Even though I knew it had some rust issues, I figured I would drive the car until I was done school, and deal with it then.
Image

Image

Image

However, on the drive back from Lime Rock for the ALMS race, we began noticing a knocking from the right front wheel. I figured it was a ball joint or something stupid, until I was able to get the car up and have a look. This is what I found.....

Image

The sway had broken the mount and was knocking a hole in my rusty frame rail. If you look at the upper control arm mount in that picture, you can see that it is basically being held in place by some type of magic. I don't have any pictures of the floors, but both the driver's and passenger side footwells had baseball sized rust holes that were filled with foam by the previous owner.

So with all the other rust issues with the car, I decided it would be best to buy a rust-free shell (as rust free as possible for the northeast) and just transfer all my parts over.....Yea...... easier said than done. So on a trip over to the local yard, I found this gem of an auto cirrus/black 528e hidden in the weeds where it had been for the last few years.

Image
Image
Image

As rough as it looks, it actually was pretty sound. All the spots on my car that were rusted were in great shape on this one. It had a straight body, a clean title, and the price was right....plus it was an 88, so it came with a free harness for when I get around to that b35 swap. In addition to the harness, it was filled with a few million of these guys.

Image

Every inch of cloth, carpet, foam, or something that resembles fabric was filled with these little bastards. I have honestly never seen so many ants in one place.

I was able to pull the motor and trans at the yard and have the car towed to my house a few miles away. After getting the car to my house, I got to stripping. Everything that was not metal came out, and the engine and interior got a treatment of POR15 and brush-on rustoleum "aluminum" colored paint.


Image

Image

As of tonight, rear subframe/suspension has been installed in the new shell, as well as 90% of the front suspension (bilsteins, eibachs, st sway bars). Fenders have also been swapped since the cirrus fenders were in sad shape. I still need to swap pedal boxes, pull the motor from the black car and put it in the multicolored car, deal with the power steering lines/brake setup since the 528s had the vacuum boosted brake setup. The doors are also going to be swapped, as is the hood and trunk lid.

Im pretty sure this is going to end up a very minimalist car (with my minimalist wallet). Very sparse interior (seats, steering wheel, shift knob....thats it), no AC, simple stereo setup. I basically just want a car that I can keep driving daily, won't have to worry about control arms rotting free during spirited driving, but will still be fun to drive (like it was). I'm also probably going to end up in North Philly for my last 2(ish) years of school, so I'm undecided as to how to finish the outside. I could leave the multicolored setup as a sort-of anti-theft finish, or might end up doing some sort of satin color.

More updates as they come........

Image
Last edited by Dan84na2T on Sep 15, 2009 8:33 PM, edited 2 times in total.
2ndeagle
Posts: 1140
Joined: Oct 13, 2007
Location: Los Angeles, CA

Post by 2ndeagle »

Wow. You definitely don't mess around. :up:
mogie
Posts: 2575
Joined: Feb 12, 2006
Location: Norwalk, CT

Post by mogie »

Looks great. That floor pan on the new car looks great, looks like there's no rust on the drain plugs. Congrats and keep us all posted as you keep up the good work
CSBolger
Posts: 3485
Joined: Nov 27, 2007
Location: Palmdale, CA

Post by CSBolger »

Ouch. Good luck on the parts transfer. Keep us posted.
muleskinner
Posts: 1346
Joined: Sep 08, 2007
Location: John Graham ATL

Post by muleskinner »

That's a lot of work. Amazingly, you seem to be getting it done within a short timeframe. Nice job.
Blue Shadow
Posts: 10532
Joined: Feb 12, 2006
Location: SE PA

Post by Blue Shadow »

The dealer emblem on the back of the yard find is from Otto's BMW in West Chester PA.

And for whoever thought uncracked rear bumper do not exist, it looks like this car has one. They are out there.
Adam W in MN
Posts: 5055
Joined: Feb 12, 2006
Location: Don't waste my motherf***in' time!
Contact:

Post by Adam W in MN »

Great story, but a ton of work! Good luck with it all.
Nebraska_e28
Beamter
Beamter
Posts: 9136
Joined: Apr 13, 2006
Location: Council Bluffs, IA
Contact:

Post by Nebraska_e28 »

Awesome to see stuff get recycled like that! Exactly the same thing I've done w/my current build.
winfred
Posts: 2839
Joined: May 12, 2007
Location: loserana

Post by winfred »

you cold give it a try with the vacuum booster or maybe a smaller diameter unit from another car, my e12 based shark is not a good example but its huge booster clears the m30b35
Image

it doesn't clear by much but it does
wkohler
Posts: 50939
Joined: Oct 05, 2006
Location: Phönix, Arizona, USA
Contact:

Post by wkohler »

b35 works no problem with the vacuum booster. B34 is the problem.

Good luck and keep up the good work.
winfred
Posts: 2839
Joined: May 12, 2007
Location: loserana

Post by winfred »

other then adding a vacuum port why wouldn't a b34 work if a b35 does? i don't know of any size differences between the intakes
wkohler wrote:b35 works no problem with the vacuum booster. B34 is the problem.

Good luck and keep up the good work.
Dan84na2T
Posts: 104
Joined: Jan 09, 2008
Location: Philadelphia

Post by Dan84na2T »

Thanks for the encouragement so far!

No pictures tonight, but I was able to pull all the brake/power steering stuff from the 535 and get a good idea of the brackets that I am going to need to make for both the accumulator and the coolant tank. Im pretty sure some nice heavy L-brackets will be my best bet for the accumulator, but I think I'm going to end up cutting the coolant tank bracket out of the old car and either getting that tacked in or bolt it in.


I also got both pedal boxes out tonight and the manual box half way in the 528 when I noticed that I tore the plastic angle nipple fitting on the clutch master cylinder right before I stopped driving the car, and it was not actually a bad master, which I originally thought. With everything out, I might just end up replacing it anyway, so that I don't have to deal with it later. For those of you that replaced clutch masters recently, do they usually come with a replacement feed line, fitting, and grommet, or is that something I need to order separately?

Finally, I swapped the driver's side door over today, that way I would have a window that closed in all the doors. For those of you that are body people, I really do not envy your job. I spent a good 1/2 hour to 45 minutes just trying to get a half-decent alignment on the door.

I'll try to get more pictures up tomorrow after I finish the pedal situation and maybe get some brackets made.
b35 works no problem with the vacuum booster. B34 is the problem.

Good luck and keep up the good work.
Then I'm definitely going to hang on the the vacuum booster now that I know it will work with the b35.
INTREPID 1
Posts: 241
Joined: Jul 25, 2009
Location: Orange, CA.

Post by INTREPID 1 »

Man what a lot of work!! good luck on your transformation.
1st 5er
Posts: 21966
Joined: Jun 13, 2008
Location: Cypress
Contact:

Post by 1st 5er »

Great story, keep us posted.
Murfinator
Posts: 1482
Joined: Sep 07, 2007
Location: ZION - 84032

Post by Murfinator »

For those of you that replaced clutch masters recently, do they usually come with a replacement feed line, fitting, and grommet, or is that something I need to order separately?
A few months back I converted my auto to a 5-speed. I had to order the master cylinder, line (steel and braided) and fitting separately.

You are to be commended for taking on such a huge project. Keep going! Looks great so far :up:
Jean
Posts: 562
Joined: Nov 30, 2007
Location: Sacramento

Post by Jean »

Oh wow, that's going to be a lot of work! :)
Dan84na2T
Posts: 104
Joined: Jan 09, 2008
Location: Philadelphia

Post by Dan84na2T »

So this past week, I got to spend a decent amount of time on the car, basically this is my last big push because I know once classes begin on the 31st, I'm not going to have the time to put in. Here is the b34 after it was pulled from the rusty car....

Image

And then here is the 528 with its new motor.....

Image

Image

I made a bracket for the accumulator, finished installing the pedal box with a new clutch master/feed line/angled fitting. Swapped steering columns, reinstalled all brake lines/ abs pump. The engine harness was about 75% done last night, when a nice thunder storm ended my fun, but at least the motor is in, which leaves just a nice long list of tedious tasks...
-Finish bolting on fenders (moisture barrier or whatever it is)
-Replace Passenger Side doors
-Finish engine harness
-Install Radiator (and hoses)
-Replace and install new fuel hose
-Replace and install new 1" hose pieces that go on the power steering cooler
-Install new trans mounts/driveshaft
-And much much more

I did however have a question to those have done the 5speed swap. I know I need to jump the neutral/park switch so the car will start, does anyone remember the wires/colors which these are? I keep getting refered to this site oo00oo.com, but it seems to be down. And I'm too lazy/incompetent to look it up in my bentley manual.
Also, the 528 had a different brake light switch on the pedal than the 535, would I be naive in thinking I can just cut the 528's connector off, put some female spade connectors on the wires and call it a day?

Thanks in advance!
wkohler
Posts: 50939
Joined: Oct 05, 2006
Location: Phönix, Arizona, USA
Contact:

Post by wkohler »

Wow. I'm impressed. I don't think I say that very often.
Dan84na2T
Posts: 104
Joined: Jan 09, 2008
Location: Philadelphia

Post by Dan84na2T »

Thank you Mr. Kholer. Anywho, I can now say the car is running decently well. I've been driving it on and off for the past 2 weeks, and It got back and forth from State College Pa this weekend (400ish miles) without a hiccup. I still have some interior to put back together, including installing some kind of radio. I may have had a bad in-tank pump in the black car as well, because I kept the tank/pump from the 528 in the car and it seemed to have solved my full throttle 1st-2nd shift hiccup that the car had.

Below is a picture of the current condition of the black car....The other 40% of the car is still in my driveway awaiting some sawzall love.
Image

Some little things that I noticed that were different between the 85 and 88 cars....
-Coarse Splined steering wheel in earlier/Fine in newer (well known)
-Mechanical center vent slider in earlier car /electrical in later car
-Different Abs sensors/ control arm attatchment
-Lack of tar sound deadening on later car (maybe because it was a 528?)
-Different brake light sensor (due to addition of 3rd brake light)

I do have a few last issues with the car. First, I bought the 25/19 big ST sway bars from a group buy that Steve Haygood had last year. However, because of the damaged mount in the first post, I have an overly worn sway bar bushing. After calling ST, they have no recollection of ever making a 25mm bar for the E28 and could not get me replacement 25mm bushings. Awesome. So I call Ireland Engineering because of a recent post, and they want to sell me some m5 adapter mounts and bushings for around 70 bucks because they believed a 25mm bushing would not fit in the stock 535/528 bracket. While I do agree the m5 mount would probably be superior, I think I might just pick up some universal Energy Suspension bushings and hope for the best. Anybody have any useful part numbers? Besides ST changing ownership, how do they have no records of these sway bars that I bought a little over a year ago? Would they not be in the system somewhere?

Secondly, when approaching a stop, at a very low speed <5 mph, I get a single pulse in the brake pedal that I believe is the abs pump kicking in. I don't get any abs light, but could I have a faulty sensor? I also may swap abs computers because I'm 75% sure I left the 528 abs computer in the car, and since it had different sensors, I would assume it also had a different computer?

I'll try to get some pictures of this multicolored beast tomorrow.
Nebraska_e28
Beamter
Beamter
Posts: 9136
Joined: Apr 13, 2006
Location: Council Bluffs, IA
Contact:

Post by Nebraska_e28 »

Did you paint the new car or did it just need a good cleansing?
Dan84na2T
Posts: 104
Joined: Jan 09, 2008
Location: Philadelphia

Post by Dan84na2T »

It needed a serious cleaning. The engine bay and interior are the only thing that got a fresh coat of paint. The fenders and doors as well as the trunk lid all had to come off my original black car, so that is why they look half decent. The cirrus fenders and 1st set of black doors were pretty trashed from being bumped around in the yard for a few years.

It will most likely get a coat of some kind of satin paint just to hold it over for a while, because as soon as I get pictures up, you will see just how terrible it looks.
winfred
Posts: 2839
Joined: May 12, 2007
Location: loserana

Post by winfred »

a pulse of the brake pedal from the abs in the last few feet of a stop is usually one or more weak wheel sensors, you can measure them with a multimeter set to AC <5v scale and a good spin of the tire, you can compare one side to the other for readings, the low one is usually the dead one
MKYR
Posts: 8
Joined: Aug 05, 2012

Post by MKYR »

Hey I saw your images on your for sale thread and I was wondering how you made the extra gauges in your radio fitment
Dan84na2T
Posts: 104
Joined: Jan 09, 2008
Location: Philadelphia

Post by Dan84na2T »

MKYR wrote:Hey I saw your images on your for sale thread and I was wondering how you made the extra gauges in your radio fitment
That was basically just a piece of real carbon fiber that was cut to fit in there, then I took a hole saw and measure and cut the holes for the gauges. Easy
Post Reply