FUBAR 528e 9/15 Repairing Unibody Cracks, Cowl and B pillar

[LeiseyJr]

Acquired some genuine # matching 528e driver floor/rocker repair from Sherman. Should be getting started on that when Dad's car is done from paint.
Untitled by samleisey, on Flickr
Untitled by samleisey, on Flickr


Also got a new Aux fan in, so now I have reliable cold A/C !! For my girlfriend and guest
Untitled by samleisey, on Flickr

Ziptie is for speed!!!!!!!!!!!!!!!!!!!!!!!!

[Bonsaibacker]

There is a lot to be said for pushing the car down the freeway at 80 to find the problem. Trusting the car not to eat it and trusting your skills to cobble it home if necessary- balls!

[LeiseyJr]

There is a lot to be said for pushing the car down the freeway at 80 to find the problem. Trusting the car not to eat it and trusting your skills to cobble it home if necessary- balls!

Always got Triple AAA, and might as well get as far as you can home.

[LeiseyJr]

A/C is pretty fucking cold. Very happy with how well its cooling in Houston Traffic now, airduster and a good aux fan made a huge difference. I was genuinely flabbergasted yesterday, sitting there the compressor was cycling. Never seen that before. Usually its on 24/7 trying to cool the car down with no rest.

Feel kind've stupid for running around with the B10 chip in a stock 8:1, but its running really smooth and crisp throttle response torquing around town. Just regular Hack mechanic things.

Also about to pull the trigger on a spare dogleg. It will be my biggest purchase ever, but it's a good deal for what it is. So I will feel more comfortable pushing the car and driving it. I did rebuild that tranny and it's been going almost a 1.5 years. It's been tracked and drifted. However still just worried as they are a more fragile then the OD's. Since it is a daily will need something I can swap in pretty quick.

Not sure why everyone is so scared to replace bearing in them much easier to take apart then the G265 OD.

[LeiseyJr]

I had a hunch that the 1:1 on both the dogleg and G262 4 speed must be the same gears, and maybe even input shaft. RealOEM only has those numbers in sense of gear repair kits. Not individually so I could only verify by getting the parts in my hand.

The dogleg and 4 speed use same front bearings, same bearing in the input shaft as well as same front case as a G262. They're also both 1:1 in same place, so you would think the engineers would reuse the gear. There was someone selling a torn apart G262 on ebay, messaged him and scored 4 syncros, input shaft, and layshaft for $180 from a "30K mile transmission". It was a gamble, but if it worked I had a chance at repairing this other dogleg. I have located a buddy with a 50 ton press, to press the gears off the layshaft.

Untitled by samleisey, on FlickrUntitled by samleisey, on Flickr

So in theory I can fix the 1982 dogleg. It's obviously not a easy feat, but possible now. With how low I paid for this transmission I should still be in green after I replace whatever bearings I need to. This will be quite a project though. It's been apart and moved around so much, hopefully still got all the pieces it needs. Fuck it though, its already trashed can't make it worse might as well try to fix it.


Press fit by samleisey, on Flickr

So this with floor repair are the next big projects in the saga

[LeiseyJr]

Found original ad. Just hit me I've owned this car for 5 1/2 years, so that means it has occupied 25%ish of my life. Wild.

[LeiseyJr]

Another Engine Pull debacle, there will be general pics of the fun after this tech tip.

On headers where it's really tight and you have a nut that takes a 1/6th of a turn with a wrench that you already broke loose. Use one of these bad boys:

Updates by samleisey, on Flickr


Gives you just enough leverage to take it off and lets you actually turn it more than a nano-meter at a time.



Updates by samleisey, on Flickr

Harness all Disconnected

Updates by samleisey, on Flickr

R.I.P another A/C belt

Updates by samleisey, on Flickr

Power Steering Pump dangling by the lines

Updates by samleisey, on Flickr

Header clearance is a yikes....

Decided to use the block drain this time, what a experience that was.


First thing is, coolant really comes out of this one. It is quite fast.
I developed a ingenious drainage system, the Egyptians would've been envious of my irrigation skills.

Updates by samleisey, on Flickr

Until well gravity kicked in and top pan fell.

Updates by samleisey, on Flickr

Updates by samleisey, on Flickr

Updates by samleisey, on Flickr

Updates by samleisey, on Flickr

[LeiseyJr]

Swap by samleisey, on Flickr

Yoinked the bad girl out


Due to space constraints engine pulls are a 2 step job. So pull engine roll car back, then set it on lift. So we can squeeze cherry picker back around, to work on it elsewhere.
Swap by samleisey, on Flickr

Pic of it after it's out.

Swap by samleisey, on Flickr

Then it was stripped clean for the other motor.

Swap by samleisey, on Flickr

All the goodies moved over

Swap by samleisey, on Flickr

This right here, is why engine installs are such a bitch. Exhaust shop made it work, for servicing it is less than ideal. So first you lower engine in, low, like below studs to get header on. Then you push engine left, hold gaskets up and force header on. This is a 2 man job, I think last time I did it by myself. It was a true nightmare. Next part is jacking it back up, and getting it on passenger mount (mounts are mounted in subframe). Then you loosen left engine mount aim, it towards the slot and have someone lower engine. You should end up with something like this:

Swap by samleisey, on Flickr
Swap by samleisey, on Flickr

[LeiseyJr]

Untitled by samleisey, on Flickr

[LeiseyJr]

So two big things happened today got a extra dogleg and motor started.

I saw this car listed on FB marketplace some clown had listed it, saying he'd pull parts. He didn't reply to my messages but odly enough he replied to my girlfriend said $1250. Which was a hard pass from me. Someone actually went through the effort of tracking car down to the yard. I got the coordinates and doglegs are my version of heroin so I was on my way.

I had work off today cause I had to see G.I Specialist. So I packed the night before hoping it'd be all I need. Guy told me exhaust was cut by header.

Untitled by samleisey, on Flickr

Untitled by samleisey, on Flickr


Anxiously I headed there, and major roadway was shut down. So that added to the anxiety of wondering whether it'd be there. I'd never been to this yard before so it was new. They had new cars on right side, and old cars on left. It was split down the middle with a fence, and in the middle of the fence there was a gate. It was open so I dodged past them lifting and moving cars didn't think much of it. I then went wrong way, I was pretty hot at this point and getting annoyed. I wasn't sure it was still there as computer lady said there were no old BMW's and it's grey market so explaining 1978 635csi is tough. I checked last quadrant and finally stumbled upon it.

https://flic.kr/p/2gWFh7V by samleisey, on Flickr

A real euro m90 dogleg e24. It had swaybars, lowering spring poly bushings, newish A/C compressor. It had quite a bit of uhhh rust

Untitled by samleisey, on Flickr

Drivers rear floor pan was not looking pretty. Quite nerve racking since I'd be laying under it. Only LF and RR corners were supported. The other two were there, I added tires under all 4 wheels and got to work removing trans. Took first the 3 driveshaft bolts out, was easy enough. Pried it down and removed CSB so it was just hanging there. It was annoying being there, but worked around it. Then I removed slave, why e12 based cars have hard line for slave is beyond me. I bent it out of the way.

The real bear with the 4 nut design on the G265, is the top left nut. Usually I use a crows foot on that, luckily I packed the god tier BMW 17/19 wrench. The fix all. Whoever did the clutch over torqued the fuck outta of these. So crows foot was not working. Luckily 17/19 was fitting just enough to loosen it like 1/8 of a turn. However it was tight as shit, but I used cross member as lever, prying from trans tunnel against wrench and it came loose. Repeated same for top right side except using exhaust pipes as a place to pry.

Used cheater wrench on bottom ones, and top left nut was coming out with stud. Which was shitty but not the end of the world. Just pull trans back and keep working stud out.
I was then stuck here:
Untitled by samleisey, on Flickr

I did not have as much room as I thought with the exhaust situation. So the next hour was wrestling this trans out, what made it 8x harder was whatever ape cut exhaust had made a lip. Plan was to get it far enough back as I could. Then tip input shaft down. I am not a very big guy, not very tall at a staggering 120lb, but I was desperate so I wrestled though it. Laying on rocks in 100 degree heat, wishing I had brought a sawzall was not a fun experience. After 45 min of wiggling praying and just persistence. Actually cut into the aluminum in some places but it
Led me to hear:
Untitled by samleisey, on Flickr

This was by far the hardest part of this, this last couple inches. Trans was wedged in all the way up into body at this point with exhaust pressing it up. With some careful prying and again more persistence. Input shaft finally fell below bell-housing. I knew I was in it to win it at this point. Trans fell quite suddenly just missed my ribs, that was neat.

Untitled by samleisey, on Flickr

Leaving me with a beautiful sight. The saga did not end here, as I still didn't have a cart. Tried to ask a man to watch my tools, he didnt speak English. So I just left all my shit and luckily found a cart. Handles were quite hot so I had to spit on handle to not burn hands. That was neat. I already finished water and it wasn't getting any colder outside. It was about 102 out and I was pretty beat from wrestling trans. On my quest to find a cart I saw the gate was closed I that got me through left side of the yard, so now I was completely confused. I wasn't sure too leave if I had to go all way around the dividing wall (go up turn right) and then the full length of the fence back. This was far too long of a walk, with how tired I was. I saw people walking down along fence line earlier , and didn't see them anymore. Assumed that must be exit. That cart pull was quite miserable, ended up being the right way.

I then paid $174, for that whole experience and for this sight.
Untitled by samleisey, on Flickr

It had blue marks between front case and rear case so maybe it was serviced previously. It is missing left side mount, not sure why BMW only mounted trans on right side. I think a adapter can be made mounting to case bolts out of steel. If not, won't run one fuck it. This will be a spare, but I will need to install it to see if it works (if it rattles or grinds every gear) before I rebuild it.


Also got my car started:
https://www.youtube.com/watch?v=MEk2Oj7b-Fg

An eventful day.

[Tiit]

Thanks for sharing your experience. But why not taking the bell housing as well? Might be handy in future.

[Bonsaibacker]

Great score and you earned it. Was wondering about the bell housing too but I can only imagine you were shot AF after puling the trans. Congrats on firing up the transplant too. Ready for next post...

[LeiseyJr]

Thanks for sharing your experience. But why not taking the bell housing as well? Might be handy in future.

Already have a extra Ljet one with a G265 OD my dad bought, if it would've been motronic. I'd have snatched it.

[LeiseyJr]

https://www.youtube.com/watch?v=Ixq2RXS9vNE

Vid of cam being broken in, car runs and drives however. After taking it around the block in the rain, left a rainbow trail. Leaking oil from pressure sender, and dripping all the way down to passenger side. So I put a new crush washer on last night, fired it up this morning no oil under sender now. Think its fixed, we'll take it on much longer drive after work today.

[LeiseyJr]

Daily Duties, has been really good on gas actually. Well better than I thought it would do, a tank week ain't bad. At 600 miles now, car feels great very happy to be driving it everyday. It does 15 miles of stop n go in the morning, then cruises home in the afternoon. It's been 95+ heading home everyday according to OBC, heat soaks and loses torque but doesn't ping. Still need to install wideband...

Daily Duties by samleisey, on Flickr

Still some annoying issues, little things. The mysterious left rear running light issue has comeback, something with checkbox or wiring. If you smack taillight it comes back though, or go over a bump will come back on. RF turn signal since a/c fan has been installed has been quite flakey, so I lose that occasionally it's plug itself or wiring. That is slowly becoming infuriating. Also gear knob vibrates, under high load or rpm. Reminds of my friends S13 when he had a short shifter with a brass bushing. Either trans is about to blow up, or the E28 Goodies Poly Shift bushings I installed have added some NVH. So might need to drop trans and add some stock bushings. Doglegs use a super long bolt instead of the allen bolts to secure this: https://e28goodies.com/product/polyamid ... old-style/. I dont care about play in shifter, but vibrating rattly knob makes me worried. It also still clunks in parking lots, when turning wheel. Ground Control Race Plates, with no Torrington Bearings on springs was not a big brain move. So springs are clunking and binding as to be expected. Just gonna keep driving that bitch though.

Also got another damn ecu, was a good deal... this is the last one...
Daily Duties by samleisey, on Flickr

[LeiseyJr]

Untitled by samleisey, on Flickr

Untitled by samleisey, on Flickr

Mhm by samleisey, on Flickr

Also finally replaced my ignition switch, I had one sitting on my desk for like maybe 2 years now. Finally decided to throw it in glad I did.....
Mhm by samleisey, on FlickrMhm by samleisey, on Flickr


$200 every 2 weeks is my current income. Which is pretty ass, but I also don't have a mortgage to buy or anything. Just food, car parts and gas. I am grateful, still allowed to do the internship better then no money coming in. Plus interning for a real company should come in handy later.

I had to buy new reference sensors (throwing parts at hot start) and new moosehead control arm bushings (RF one fell apart... long story). I also had to buy 2 new RE71R's and a GREAT deal came up on new Toyo RA1's ($300 shipped for 4) so I can finally have a set of TRACK ONLY tires. Someone also invited me to a track day the 22nd, so gonna keep going into the red I guess money wise. Sophomore year is also kicking my ass, but one day at a time. Gotta train to be a wageslave for the racecar parts. Honestly keeping my eyes peeled for something that's not wageslave like, but until then might as well get the piece of paper that says I can work for someone.

[LeiseyJr]

As of writing this it has 2410 miles on the new motor and a trackday.

Car also survived another Houston Monsoon
Update by samleisey, on Flickr
Update by samleisey, on Flickr

Only reason I didnt die was because I had full tread RA1's.

Re71R's in standing water are hot garbage.

Pic of car at work/school/track

https://www.flickr.com/photos/132920043 ... 803824361/
Update by samleisey, on Flickr
Update by samleisey, on Flickr
https://www.flickr.com/photos/132920043 ... 803966892/
Update by samleisey, on Flickr

Here is a vid of me chasing 911. Excuse my inability to be able to mount a go pro at center of screen, as it tries and auto exposes center console. I really liked the RA1's pretty sure they slower full tread, but I really liked them. D

https://www.youtube.com/watch?v=A1uZ2sAxA7A

Excuse List:
Had to keep it in 4th, in back half of track before back straight (need catch can)
Engine was way down on power 10.5 at full throttle

However,
Car setup feels phenomenal, LSD still needs rebuild, and rear shock rebound is a yikes and some more driver mods definitely needed. I couldve been way deeper in the brakes going over the launch.

Very happy with setup, just need to fix tune and catch can. Should be mint.

Oh yeah A/C compressor is heading out, which is a shame because it blows cold.

[LeiseyJr]

Fall weather has arrived time for a update.

This happened recently, something sounded slightly off on start up, in the garage. I usually don't park there so it changed the harmonics. Sure enough:

Untitled by samleisey, on Flickr

Untitled by samleisey, on Flickr

I had quiz in a class coming up. So I tensioned it with a pry bar, tightned the shit out of bottom bolt and used bailing wire so it couldnt completely flop loose. Made the 47 miles to and back from school.

Also changed the blower motor (new one failed, used one I put in smelled like electrical fire) to a good used one from South26, and my god does that make a difference. A silent source of fresh air, and fall has arrived. So fixing A/C just got pushed way back.

I also installed Nardi sans horn button. I really like this wheel, super sturdy. I do miss the horn button and maybe a black one would look better. For $110 though, well worth it.

Update by samleisey, on Flickr
Untitled by samleisey, on Flickr

Untitled by samleisey, on Flickr

I also put the 02 sensor back in, and Dad was right. It's night and day did that because my wideband died. So finally had a reason to crawl under there.

[LeiseyJr]

Untitled by samleisey, on Flickr

[1st 5er]

Gonna miss that beast at Canyon Lake this weekend.

[LeiseyJr]

So uhh here's a update.

2020 update by samleisey, on Flickr

Let's rewind. I did end up going to tex-fest. Just to show my face, that was a sudden impulse decision. It was a good road trip, the last road trip on the Korman chip. Saw some cool cars, played Uno with Eric (hitmanx) and pals. It was nice to see everyone, even though I was barely there.

2020 update by samleisey, on Flickr
2020 update by samleisey, on Flickr
2020 update by samleisey, on Flickr
2020 update by samleisey, on Flickr

So that happened, then the tuning process begin. So daily driving the car switching between tunes trying to dial it in. I also changed the diff, and unfortunately where my hangar mounted to was broken on this diff. So bailing wire has been holding it up for several months now. That's cool.

2020 update by samleisey, on Flickr
2020 update by samleisey, on Flickr
2020 update by samleisey, on Flickr


This was a shitty semester academically for me. I ain't that bright and Calc 2 and statics destroyed me and then in my easy class the professors were doing some clown stuff that shafted me. So I got lower grades then expected. We'll come back next semester.
2020 update by samleisey, on Flickr

One day during that I decided to flash my ecu on windows 10 and broke the chip. So that was neat. I had to install a windows virtual machine at school in the food court, I somehow got it with tunes flashed onto it.
2020 update by
2020 update by samleisey, on Flickrsamleisey, on Flickr

Thanksgiving happened, went to go see my grandparents. Car did the trek perfectly fine even got 20 mpg!!!

2020 update by samleisey, on Flickr

I also visited what remained of my childhood racetrack.
2020 update by samleisey, on Flickr
2020 update by samleisey, on Flickr
2020 update by samleisey, on Flickr
[url=https://flic.kr/p/2i8Tz9K]2020 update by samleisey, on Flickr

After that was finals, this was my hardest last test. Telling which one was mine. These damn beige econoboxes just all look the same.
Untitled by samleisey, on Flickr


and finally winter break. I have been going to Catalina Coffee car meets every Sunday, just because.
2020 update by samleisey, on Flickr
Untitled by samleisey, on Flickr
Untitled by samleisey, on Flickr

I really want my car to be a similar version of these.
2020 update by samleisey, on Flickr

Onto the good ol changes. I dialed in the M1.0 idle as best as I could. I wanted smoother so out came the M1.3 parts. So one day at a big oil company where I intern, I naturally labeled my M1.3 super eta harness and re routed what needed to be re routed from super eta harness.
2020 update by samleisey, on Flickr

I only had to extend the oil pressure switch areas. I just removed stuff from the loom and moved it where it needed to go. It plugged right in and fired up. I did have issues flashing miller with 179 tunes, but I eventually got it sorted.
2020 update by samleisey, on Flickr

Messy but functional.

Then to test it out my M1.3 swap I went to a weird event, drift/autox at Houston Police Academy. It was essentially a rented out track with people hotlapping. It was hard to get clean laps in grip driving. However it did present a problem with M1.3, the adjuster nut for the crank sensor was loose. So it began to cut out at this event, I had to leave the event early because grandparents were coming into town. I did figure it out there though, when it finally slipped down when CPS was rubbing on the wheel it was supposed to be reading. The amazing thing was car was still running as they tried to grind themselves apart. I adjusted that to spec with a business card and we were back in action. The Houston Chronicle also came and wrote about us, so this old shitbox made the newspaper.

https://www.houstonchronicle.com/news/h ... ron-result

2020 update by samleisey, on Flickr
2020 update by samleisey, on Flickr
2020 update by samleisey, on Flickr
2020 update by samleisey, on Flickr

For my birthday, my girlfriend bought a Windshield from Sherman for me. Unfortunately...
2020 update by samleisey, on Flickr

So I instead traded that for truck carpet and some other tid bits
2020 update by samleisey, on Flickr

We also pulled this dash for my dads car while we were there:
2020 update by samleisey, on Flickr

I also treated myself this Christmas to euro bumpers. Which has no revealed my Fubar tail panel. Don't wear a thong with an eyesore of an ass.
2020 update by samleisey, on Flickr
2020 update by samleisey, on Flickr
2020 update by samleisey, on Flickr

The front bumper situation, not sure what to do there. My frame rails are bent, so even if I do complete the pieces I have for a euro front its gonna be crooked. So front will remain the same most likely.

I also changed the fuel pump, I think it has sorted the hot start issue.

Plans for 2020:
Focus on school
Just drive this bitch, fix cheap little things. Clean up interior. Preserve exterior. Try not to go to any events, just for once save up some money and really focus in school.

SHAMELESS PLUG: PM if you want one $7 Shipped
Untitled by samleisey, on Flickr

[LeiseyJr]

To make a long story short, I had to fix my clutch pedal. Master cylinder died, so it got a new one. Took forever to bleed it and get it right but it finally happened. I then proceeded to send 5 hours shining shit, aka un shadowlining the rear bumper.


Euro by samleisey, on Flickr
Euro by samleisey, on Flickr
Euro by samleisey, on Flickr

[maybeillbuyit]

Wow, you found a dogleg in a yard. Not many yard pickers will ever be able to say that. Congrats. That would be the highlight of my year. What ever happened with fixing the original dogleg with the 4 spd parts? I have a very old suspect dogleg might need that fix someday.

[LeiseyJr]

Wow, you found a dogleg in a yard. Not many yard pickers will ever be able to say that. Congrats. That would be the highlight of my year. What ever happened with fixing the original dogleg with the 4 spd parts? I have a very old suspect dogleg might need that fix someday.

http://www.mye28.com/viewtopic.php?f=7& ... g#p1402603
I have found 2 in the yards, and one for $5 (trade for e34 m50 dipstick). Law of attraction and good luck are all I can contribute it too.

They all need layshaft bearings, unless you have some known low mileage ones that dont rumble. Anything even 150k+ should have it done I would say.

That trans is apart right now, the layshaft has been repaired with a G262 4th gear. So we now have 5 gears with all teeth again. My dad is machining the Input shaft out, and pressing a in a collar for the bearing that rides in it. Then after that, the painful process of reassembly will begin. I only needed 4 speed trans because, when layshaft bearing went it took all the 5th gear teeth with it.

[tschultz]

No plans for front bumper??

[gaberdee]

Crackin me up. Like this build a lot, nice work man!

[LeiseyJr]

No plans for front bumper??

maybe....

IMG_6343 by Kurvenkamph Motorsport, on Flickr

IMG_6317 by Kurvenkamph Motorsport, on Flickr

IMG_6311 by Kurvenkamph Motorsport, on Flickr

IMG_6308 by Kurvenkamph Motorsport, on Flickr

[LeiseyJr]

It's quite rough. All the rubber trim is held on with zipties, and the plate cover is cracked and held together by zip-ties. It's screwed in though.

The front bumper chrome is quite horrid on corners, that's why p/o painted it black. Luckily, it has "patina" for the car.

I also forgot how fucked, left frame rail is.

Reduce reuse and recycle?

I could drill into them from the back with screws, seems more destructive then just having zipties. So idk if it's much better. That feels scummy to me to hide that, rather have zipties showing that I cant afford OE mounted shit. Then screwing into stuff from behind drilling more holes, hacking more stuff up. I'd rather have messed up chrome, then it hiding underneath black paint.

I want this car to look honest.

The foglights are expensive holes to fill, but we'll figure it out.
It looks better, but has changed ethos of the car. I am not that pleased with the end result, but the parts were not that good to start with.

I am happy, in that it's all installed and can only get better from here.

[Tiit]

Zip ties will do. It’s perfect.

[1st 5er]

Dat paint doe!!! Looks super.