Project e23 B9 build - update 11/25/19

[RoyW]

Was it Furniture Clinic by chance? I really like their product line

Yes, that's it Furniture Clinic Thanks.

-RoyW

[RoyW]

Got back home from FL early last week and ready to continue work on the e23 B9 project. However, as is usually the case with a project car, there have been a couple of delays in the plan and schedule... the engine re-build didn’t get completed as we had hoped during the Jan thru March time-frame. Turns out that a complete engine re-build is needed, not just the head and bottom-end refresh as we had hope Upon engine dis-assembly, Steve discovered that the clearance between pistons and cylinder wall were well out of spec and the upper ring on the pistons were all wavy and had that ring groove clearance well out of spec… this, despite good compression and leak-down numbers from the PPI? Also, the crankshaft needed some work... so, that repair & polishing is required, plus a new bearing set was ordered. The block will now be honed, etc., for the new pistons & rings.

In addition to this added engine work, there was an extra delay in getting new custom pistons made, since these are Alpina specific and NLA. We just received the piston set this week (from Wiseco) and I also picked up the re-built head from VSR… all are beautiful and shiny So, as soon as the machine shop can get to the block with the new pistons, my good friend and ace mechanic, Steve, will be able to begin the engine assembly process… maybe another month for completion? Fingers crossed.

Steve did get a bunch of engine components cleaned up and painted during the past couple months, so all is ready and awaiting the finished block and crank, new pistons, new bearings, etc., We’re hoping to get the engine back in the car by sometime in May. Meanwhile, plenty of other work to do, e.g., re-finish brake calipers, install new carpet set, clean-up and assess dozens of parts from initial tear-down, pull needed parts from the 733 parts car, etc., etc.

Yesterday I picked up the re-built and re-leathered back seat bottom that was trashed in this car. I couldn’t find a good used one, so I had the original re-stored by Custom Leathers in Ludlow, MA. Also picked-up (at local BMW dealer) the brand new dash I had ordered for this e23… now to find somebody who knows what the hell they're doing (has experience) and can install it at some later date in 2018… Bueller?, Bueller?, Kohler?, Kohler????

Here are some pictures of the aforementioned items. Onward and upward!!

-RoyW

20180404_174751 by Roy Wicklund, on Flickr
20180404_174744 by Roy Wicklund, on Flickr
20180404_174732 by Roy Wicklund, on Flickr
20180404_174727 by Roy Wicklund, on Flickr
20180404_174724 by Roy Wicklund, on Flickr
20180410_142203 by Roy Wicklund, on Flickr
20180410_142109 by Roy Wicklund, on Flickr
WP_20180409_17_36_37_Pro(1) by Roy Wicklund, on Flickr
P1060468 by Roy Wicklund, on Flickr
P1060471 by Roy Wicklund, on Flickr

[RoyW]

Finished up the refresh on the brake calipers yesterday... all re-built (Steve), primed (POR-15), and finished with G2 caliper paint kit. Ordered new bleeder valves, awaiting delivery. I plan to tackle the front seat bases, which are pretty scratched up, this weekend.

Late next week George, aka geordi (and maybe Aaron, aka ahab) is/are coming out for a wrenching weekend. Should make a lot more progress

-RoyW

P1060473 by Roy Wicklund, on Flickr
P1060480 by Roy Wicklund, on Flickr
P1060481 by Roy Wicklund, on Flickr

[ElGuappo]

Look at all those sexy pistons...

[Pavel]

E23 extravaganza!

[RoyW]

Look at all those sexy pistons...

pistons... engine or calipers?? I kinda like the sexy valves.

-RoyW

[ElGuappo]

Look at all those sexy pistons...

pistons... engine or calipers?? I kinda like the sexy valves.

-RoyW

Calipers!
That's like 3x more than an E28 has.

[Hffvdbl]

Nice progress guys! Thanks for the updates

[RoyW]

This past weekend was a busy one on the e23 B9 project, as George and Aaron were here at the house/AutoBahn to help lead the charge on pulling the engine and tranny (and other quality parts) from the 733 parts car... and, we did some further clean-up on the B9 engine bay and those earlier removed parts that will ultimately go back on the car.

A huge shout-out to Aaron for showing George and I how to quickly and successful remove an M30 from said 80’s BMW… also thanks to Pavel for suggesting we cut away the front end of the 733 donor to make things easier. All-in-all it went great… had the engine/tranny out in about 4 hours. Also, we removed the clutch, flywheel, fuel pump, compressor, power steering pump, wiring harness, wheels, etc., etc. , as many of these items are spoken for or will be sold to offset the cost of the parts car… of course, some small common parts, still on the parts car, will be use on the B9 during re-construction, if they are better.

George did a lot of wire brushing and cleaning on various parts, and we both did some restoration, e.g., cleaning, sanding, painting on these parts. Slow, but sure, forward progress, while awaiting the machine shop and engine re-build. Planning to pick up some parts that will converge at The Vintage in a few weeks (and deliver some as well ). Hoping to have the engine back in the B9 in May, and head to VSR for body and paint work sometime in June… we’ll see.

Thanks again Aaron and George for all the help… you guys are the best!

-RoyW

P1060516 by Roy Wicklund, on Flickr
P1060521 by Roy Wicklund, on Flickr
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P1060605 by Roy Wicklund, on Flickr

[tig]

Good guys. All around.

Glad to see that NSX is still there under cover waiting for me to come pick up someday.

[1st 5er]

Lookin' good.


Glad you found something George can do other than flip burgers.

[RoyW]

Good guys. All around.

Glad to see that NSX is still there under cover waiting for me to come pick up someday.

Come on out and take her for a spin... you be buying one for sure after that experience Planning another BBQ at the Bahn later in the Summer or early Fall... perfect time for a trip East

-RoyW

[Chimi-Changa]

Nice Pull!

Look forward to the summer party already

[tig]

Good guys. All around.

Glad to see that NSX is still there under cover waiting for me to come pick up someday.

Come on out and take her for a spin... you be buying one for sure after that experience Planning another BBQ at the Bahn later in the Summer or early Fall... perfect time for a trip East

-RoyW

Oh, I don't need any more motivation. Remember you already let me drive it?

[Pavel]

glad i could be of assistance.. remotely.

[RoyW]

Over the past 12 weeks the B9 engine (Alpina engine #3449) has been in re-build mode with custom pistons being made, crankshaft machined & balanced, block honed, new bottom-end components, complete head re-build, new timing components, ancillary parts cleaned and painted, then all was assembled, sealed & oiled, etc., etc. In addition the gearbox was re-freshed, tranny fluid changed, and a new clutch installed. My friend Steve has managed this process, worked with the involved subs, e.g., Wiseco, machine shop, VSR, etc., then he assembled the engine. This past Tuesday the “new” engine (with tranny) was transported to the AutoBahn and we installed it in the car…. things went well with no real issues. There is a lot more to do prior to starting her up… but at least for now the engine is in place and it’s on to the next set of tasks. I have a long parts list to source from either the parts car; other used/re-furbished sources; or buy new. No date has been set for the next wrench session, but I’m guessing Sept. after body and paint, which is planned for Summer?

After we completed Tuesday's engine install, Steve, pretty much single-handedly, tackled the removal of the badly cracked dash (I have a new replacement one), then the HVAC controls and the heater box, (needs re-building). I was busy bagging and tagging fasteners & parts and finding and handing off the necessary tools to Steve… I felt like a nurse in the OR , … anyway, what a nightmare! The e28 dash on Project Sepang was far easier to remove! And, as for the HVAC controls and heater box, there was some damage to the controls frame and a couple un-explained items in the rats-nest of wiring that seemed out of place (we think), probably caused by a radio swap with additional stereo wiring from some past owner? The removal of the blower assembly and then the HVAC box itself was a real PITA… not German engineering at its finest IMO. I can’t imagine how challenging it will be to re-install all of this after Pavel re-builds the box and controls and returns all to me (you are the man, Pavel!)… but, that’s a ways down the road

So, that’s it for now. I’m hoping to get the car up to VSR for body & paint work in the near future (July?)… working on that schedule as we speak. Then we will work on re-assembly of the car inside and out, and of course completion of the driveline and all mechanicals… not the ideal sequence of events, but it is dependent on the availability and schedules of the many great resources contributing to this build.

Here are some pictures of the past 3 months work, somewhat in order of completion.

-RoyW

20180516_180034 by Roy Wicklund, on Flickr
20180519_092947_006 by Roy Wicklund, on Flickr
20180519_104622 by Roy Wicklund, on Flickr
20180526_161217 by Roy Wicklund, on Flickr
20180527_161148 by Roy Wicklund, on Flickr
20180527_162226 by Roy Wicklund, on Flickr
20180603_092926 by Roy Wicklund, on Flickr
20180526_163743 by Roy Wicklund, on Flickr
P1060674 by Roy Wicklund, on Flickr
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P1060685 by Roy Wicklund, on Flickr
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P1060696 by Roy Wicklund, on Flickr
P1060701 by Roy Wicklund, on Flickr
P1060703 by Roy Wicklund, on Flickr
P1060704 by Roy Wicklund, on Flickr

[TurboE28]

Awesome!!

[tig]

I never tire of engine build prOn. Thanks for sharing Ron.

That period where the built engine has been installed, bit you can't start yet is super nerve wracking for me. Don't forget to put oil in. I have a buddy who had a long 'installed but not run' period and he forgot he didn't put oil in. Sad, sad story.

[gray635]

Roy:

Great to see you again at Vintage this year in the Sepang car! I continue to follow this build thread with much interest. Amazing stuff. Top work.

Regards,
Mike

[RoyW]

Slow but sure progress on the B9 this past month.... onward and upward!

- cleaned up more surface rust in a few spots;
- cleaned up and painted inside of rear valance;
- removed badges from trunk lid;
- had injectors serviced;
- re-finished wood trim from glove box (dash was removed last month);
- prepped valve cover for paint;
- and, most importantly, brought the B9 up to VSR last week for Phase 1 of body & paint work, namely corrosion repair.

Expect to get the car back in a few weeks, as I'm hosting a wrenchfest weekend (Steve, George, Aaron, Pavel, Jim, etc.) just after Labor Day, where much of the mechanical work yet to be done will commence. The car will then go back to VSR for Phase 2 , i.e, final paint prep and paint, sometime after we get it put back together, mechanically speaking (not trim or interior, etc.). So, maybe late in the year or early 2019 depending upon VSR schedule? This way we aren't working on a freshly painted car, but at least all the corrosion will be repaired on the body so when it's hopefully running, it can then be painted. After that the interior, dash, windshield, trim, probably exhaust, and other items can be completed. New target for completion is Vintage 2019.

Here are a few pics of the completed tasks referenced above.

-RoyW

P1060770 by Roy Wicklund, on Flickr
P1060769 by Roy Wicklund, on Flickr
P1060787 by Roy Wicklund, on Flickr
P1060789 by Roy Wicklund, on Flickr
P1060790 by Roy Wicklund, on Flickr
P1060774 by Roy Wicklund, on Flickr
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P1060792 by Roy Wicklund, on Flickr
P1060797 by Roy Wicklund, on Flickr
P1060793 by Roy Wicklund, on Flickr
B9 at VSR for corrosion repair 2 by Roy Wicklund, on Flickr
B9 at VSR for corrosion repair 3 by Roy Wicklund, on Flickr
B9 at VSR for corrosion repair 1 by Roy Wicklund, on Flickr

[RoyW]

Over the past 3 weeks the B9 has been up at VSR having all the corrosion issues addressed… and there was much more than expected and first seen… but, when you start taking panels off and digging into bad spots there are always new discoveries Issues were addressed on both front fenders, all 4 doors, trunk edge areas, trunk lid, rear quarter panels, spare tire well, gas pedal at floor, front footwell corners, ends of rockers front and rear, etc., etc. But after many, many hours (did I say many?:) of quality VSR labor and materials, all is resolved and after the next few months of mechanical work getting her put back together and hopefully running, she’ll go back for paint prep and paint, and then back home for finally assembly (he said optimistically)

Here are a bunch of pictures of the bodywork while the B9 was up at VSR. She is now back in the AutoBahn where major work will commence the weekend after next… meanwhile I’m cleaning parts (old ones), assess those parts, ordering needed items, cannibalizing the parts car, trying to find those that are NLA, and organizing and labeling everything for the upcoming re-build.

P1060801 by Roy Wicklund, on Flickr
P1060802 by Roy Wicklund, on Flickr
P1060803 by Roy Wicklund, on Flickr
P1060804 by Roy Wicklund, on Flickr
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P1060854 by Roy Wicklund, on Flickr

[Adam W in MN]

Wow that's a lot of body repair, but keep at it Roy! I can't wait to see the finished car.

[1st 5er]

How are/were the brake lines?
I only ask due to recently having to retire an 87 is due to brake line failure due to rust..

[Foonfer]

Not sure how I had missed this thread, it is nothing short of amazing.

I know I sometimes sound like a broken vinyl and that we are talking rarefied Alpina-ese here, so please don't take this as an insult but- BUT- Never fails to AMAZE me how Style 29 wheels, a design which surfaced long after the E12-E23-E24-E28 were phased out, can and still looks like it could have been intended for these body styles. They look SO GOOD on these cars.

Love this effort. Not only because of the car itself (which would warrant a lot of attention on its own) but also because I'm not entirely sure what does it take. Certainly takes time, space, money and skill... but it also requires friends, a modicum of marital comprehension, and I guess laser focus on a goal. Whatever it is, I salute you.

[RoyW]

How are/were the brake lines?
I only ask due to recently having to retire an 87 is due to brake line failure due to rust..

The hard brake lines show corrosion, but not to the extent of needing replacement (not yet anyway) I had VSR take a look as well and they agreed they were serviceable.

-RoyW

[RoyW]

Not sure how I had missed this thread, it is nothing short of amazing.

I know I sometimes sound like a broken vinyl and that we are talking rarefied Alpina-ese here, so please don't take this as an insult but- BUT- Never fails to AMAZE me how Style 29 wheels, a design which surfaced long after the E12-E23-E24-E28 were phased out, can and still looks like it could have been intended for these body styles. They look SO GOOD on these cars.

Love this effort. Not only because of the car itself (which would warrant a lot of attention on its own) but also because I'm not entirely sure what does it take. Certainly takes time, space, money and skill... but it also requires friends, a modicum of marital comprehension, and I guess laser focus on a goal. Whatever it is, I salute you.

Thanks. You hit the nail on the head regarding what it takes... also, a little crazy and vintage BMW sickness to boot

[Pavel]

P1060703 by Roy Wicklund, on Flickr

Shipping back to you, tomorrow.

[RoyW]

All ready for this weekend's wrenchfest and BBQ.... B9 in position; tools ready; parts cleaned (or new), sorted, labelled, and ready for install Hoping to make some good progress with engine accessories, wiring harness, driveline, brakes, HVAC box, etc. Plus lots of good food, beer, and car talk with great e28 friends. Stay tuned!

-RoyW

P1060890 by Roy Wicklund, on Flickr
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P1060887 by Roy Wicklund, on Flickr
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[1st 5er]

All ready for this weekend's... food, beer, and car talk with great e28 friends. Stay tuned!

-RoyW

I know you'll have great success with that group of knuckleheads.
Sorry I'm not amongst them there, but will join in the .

Y'all ENJOY!!!

[Nebraska_e28]

Sorry I can't make it, but will be there in e23 spirit!