E28i 535i 1988 manual resto/euro conversion

[muleskinner]

That's some craftsmanship with the bumpers. Look forward to seeing the continued transformation.

[Mdreamer]

I agree with the other posters about how nice your bumpers came out. Great work!

[Rthlss1]

Great progress indeed! Are you going to notch the lower valance for the exhaust? I didn't mind a little cutting, but instead of replacing the entire back panel and risking the body going out of square, I only replaced up to a horizontal line which is hidden behind the bumper.

I've also been to Ljubljana believe it or not. Beautiful place. Was visiting American friends living/working in Villach Austria, and we spent an a day looping thru Slovenia and N. Italy.

Great progress! I truly enjoy reading up on restoration projects like this! It gives me inspiration on my own project as well as insight on what was done to achieve a solution.

side note: I used to work for a Slovenian company based in Ljubljana they took employees back to Ljubljana every year to experience the culture!

Thank you guys for your feedback!!

Again small world . Yes Ljubljana is a nice small city in a day you can see it all and in 1 hour of drive you can be in Italy, Croatia...
Zender rear bumper is going to make a lower line. I have test fitted it and adjusted exhaust end tips (shortened them and re-welded position to sit higher and in the center of Zender space for exhaust tips) to fit as nice as possible.

20220428_105309 by Jan Podržaj, on Flickr
20220428_104437 by Jan Podržaj, on Flickr
20220428_195320 by Jan Podržaj, on Flickr

[Rthlss1]

USA bumper was removed and the EURO bumper was test fitted.

20220426_173833 by Jan Podržaj, on Flickr
20220426_193449 by Jan Podržaj, on Flickr
20220426_193424 by Jan Podržaj, on Flickr
20220426_193236 by Jan Podržaj, on Flickr

And the gear shift knob is now covered in new leather.
received_406105857614193 by Jan Podržaj, on Flickr
received_680463526400069 by Jan Podržaj, on Flickr
received_416334446494087 by Jan Podržaj, on Flickr

Hopefully I get the dashboard and interior back this week so I can finish work inside the car.

[1st 5er]

Dat knob

[Rthlss1]

Got the dashboard and interior back.

20220509_153737 by Jan Podržaj, on Flickr
20220509_154125 by Jan Podržaj, on Flickr
20220509_154203 by Jan Podržaj, on Flickr

Installed everything - dash vent surprisingly fast.

20220510_172615 by Jan Podržaj, on Flickr
20220510_173145 by Jan Podržaj, on Flickr
20220510_185735 by Jan Podržaj, on Flickr
20220510_193105 by Jan Podržaj, on Flickr

New leather on steering

20220510_172232 by Jan Podržaj, on Flickr

Repaired sloppy webbing on back of the seats and shortened the plastic around bowden cable so the headrest on drivers seat works again.

20220510_174344 by Jan Podržaj, on Flickr
20220510_194124 by Jan Podržaj, on Flickr
20220510_174349 by Jan Podržaj, on Flickr

[Mdreamer]

Wow! It is coming together very nicely. This makes me wish I had the skills to do all of my own work. Sigh...

[Rthlss1]

Wow! It is coming together very nicely. This makes me wish I had the skills to do all of my own work. Sigh...

Thanks. I do it with major help from my father who is a great craftsman.

[Rthlss1]

Installed rear EURO bumper and Zender apron.

Some before/after side comparison.

20220420_171613 by Jan Podržaj, on Flickr
20220520_203435 by Jan Podržaj, on Flickr
20220520_204028 by Jan Podržaj, on Flickr
20220520_203547 by Jan Podržaj, on Flickr
20220520_203948 by Jan Podržaj, on Flickr

Wasn't able to save the original antenna (will use it for parts for other projects) so I bought another Hirschmann antenna that works perfectly and I think it is period correct as well.¸

20220516_173159 by Jan Podržaj, on Flickr
20220516_174954 by Jan Podržaj, on Flickr

[Rthlss1]

EURO goodies from Germany arrived

20220420_171613 by Jan Podržaj, on Flickr

- front metal euro valance
- NEW ZENDER ORIGINAL front apron
- MTech trunk spoiler
- euro blinkers
- another euro front chrome bumper

20220526_094024 by Jan Podržaj, on Flickr

Test fitting

20220526_201823 by Jan Podržaj, on Flickr

Due to rust on euro metal valance I only bought it for measurements to cut the holes on USA valance.

[Rthlss1]

Cut the openings to make "euro" valance.

2 by Jan Podržaj, on Flickr
20220531_172941 by Jan Podržaj, on Flickr

Test fitted front euro bumper and zender apron.

20220531_173119 by Jan Podržaj, on Flickr

Will be running fog light delete plates

[/url]20220531_181811 by Jan Podržaj, on Flickr
20220531_181819 by Jan Podržaj, on Flickr

Removed old glue and repair broken off thread from Mtech trunk lip

20220530_105309 by Jan Podržaj, on Flickr
20220601_114353 by Jan Podržaj, on Flickr
20220601_165844 by Jan Podržaj, on Flickr

There was a chip of plastic missing on Mtech plastic - I put some liquid plastic to fill it and sanded it. Since I had the plastic tube opened I cut off connectors from USA blinkers and attached them to EURO blinkers and sealed them with plastic.

20220601_114432 by Jan Podržaj, on Flickr
20220601_121033 by Jan Podržaj, on Flickr
20220601_114416 by Jan Podržaj, on Flickr

Thanks to the guy who did great write up http://speed.academy/bmw-e28-euro-bumpe ... 4716796875

Sanded rubber a bit to put some rubber paint on

20220601_171336 by Jan Podržaj, on Flickr
20220601_170601 by Jan Podržaj, on Flickr

Got the wheels back - now with polished lips and new nuts/bolts

20220602_200627 by Jan Podržaj, on Flickr
20220602_202103 by Jan Podržaj, on Flickr

[Rthlss1]

Took out the grill and headlights for proper cleaning.

20220609_172734 by Jan Podržaj, on Flickr

Polished headlight rings and cleaned grill.

20220609_190326 by Jan Podržaj, on Flickr
20220609_221359 by Jan Podržaj, on Flickr
20220609_192615 by Jan Podržaj, on Flickr
20220609_192642 by Jan Podržaj, on Flickr

Installed KAW springs - 45 mm front / - 40 mm rear. As always happy with how KAW springs feel while driving. Stiff but not hard through holes.

20220615_175421 by Jan Podržaj, on Flickr
20220615_175551 by Jan Podržaj, on Flickr
20220615_191437 by Jan Podržaj, on Flickr
20220615_191455 by Jan Podržaj, on Flickr
20220615_191508 by Jan Podržaj, on Flickr

Marked and drilled holes for Mtech trunk spoiler.

20220615_184322 by Jan Podržaj, on Flickr

Got a Zender front apron and trunk lip plastic from a paint shop and installed them.

20220623_190100 by Jan Podržaj, on Flickr
2 by Jan Podržaj, on Flickr
20220624_114029 by Jan Podržaj, on Flickr

Before/after conversion

20220420_172640 by Jan Podržaj, on Flickr
20220623_202608 by Jan Podržaj, on Flickr

Took the car to MOT - passed with no issues.

20220624_121245 by Jan Podržaj, on Flickr

Meanwhile I also bought another 535iA 156k miles from California with broken auto transmission.

20220512_174159 by Jan Podržaj, on Flickr
20220512_174348 by Jan Podržaj, on Flickr
20220512_180952 by Jan Podržaj, on Flickr

Replaced transmission and after service shifts like charm.

20220603_164946 by Jan Podržaj, on Flickr

Also I converted it to EURO look.

20220622_174123 by Jan Podržaj, on Flickr
20220622_174058 by Jan Podržaj, on Flickr
20220622_174238 by Jan Podržaj, on Flickr

Front bumper was already tucked in but still not for my taste.

20220525_181438 by Jan Podržaj, on Flickr

Got the opportunity to compare sport vs comfort seats. Must say that for e28 comfort seats are a better choice - seat armrest do the thing and soffer/longer leg support. But sport seats do look much better.

20220622_174958 by Jan Podržaj, on Flickr

[Mdreamer]

When I first opened the thread and saw your black car I thought to myself, "I thought his car was white?"

Thanks for keeping us abreast of your progress. I really like how the white car is progressing, and I agree with your findings regarding comfort versus sport seats. The sports definitely look the part, but that armrest is the business on longer drives! Are you going to keep the automatic in the black car?

[Rthlss1]

When I first opened the thread and saw your black car I thought to myself, "I thought his car was white?"

Thanks for keeping us abreast of your progress. I really like how the white car is progressing, and I agree with your findings regarding comfort versus sport seats. The sports definitely look the part, but that armrest is the business on longer drives! Are you going to keep the automatic in the black car?

Quick paint job and she is black

Thanks.

I am keeping it automatic. I drove it 300 miles this weekend and in sport mode can be driven on curvy roads as well. e36 318is and e30 325i were having trouble keeping up.

20220626_190923 by Jan Podržaj, on Flickr

[tig]

Really great work. Motivating me to do the euro swap on Maytag!

Alpine E28s converted to 6-speeds are the best.

[Rthlss1]

Really great work. Motivating me to do the euro swap on Maytag!

Alpine E28s converted to 6-speeds are the best.

Thanks. Just a few days ago I was checking your 535is zinno thread. Nice work!

From what car 6 - speed tranny is used for conversion? E39?

[tig]

Really great work. Motivating me to do the euro swap on Maytag!

Alpine E28s converted to 6-speeds are the best.

Thanks. Just a few days ago I was checking your 535is zinno thread. Nice work!

From what car 6 - speed tranny is used for conversion? E39?

Ha! Maytag's swap is a 5-speed, but the shift knob is from an E34 (I previously had an E34 540i M-Sport and had kept a semi-broken knob I replaced).

MInerva has a 6-speed from an E46 M3.

[Rthlss1]

Really great work. Motivating me to do the euro swap on Maytag!

Alpine E28s converted to 6-speeds are the best.

Thanks. Just a few days ago I was checking your 535is zinno thread. Nice work!

From what car 6 - speed tranny is used for conversion? E39?

Ha! Maytag's swap is a 5-speed, but the shift knob is from an E34 (I previously had an E34 540i M-Sport and had kept a semi-broken knob I replaced).

MInerva has a 6-speed from an E46 M3.

Lovely!

[Rthlss1]

Car had some nasty dents.

20220420_164643 by Jan Podržaj, on Flickr
20220420_164738 by Jan Podržaj, on Flickr
20220420_164743 by Jan Podržaj, on Flickr
20220420_164731 by Jan Podržaj, on Flickr
20220420_164710 by Jan Podržaj, on Flickr

I had them paintless removed.

20220702_104338 by Jan Podržaj, on Flickr
20220702_103826 by Jan Podržaj, on Flickr
20220702_104150 by Jan Podržaj, on Flickr
20220702_103941 by Jan Podržaj, on Flickr
20220702_104246 by Jan Podržaj, on Flickr

The workshop also measured the paint to confirm that the car is in original paint except the front hood. Quite amazing for the mileage it has.

[gwb72tii]

Really great work. Motivating me to do the euro swap on Maytag!

Alpine E28s converted to 6-speeds are the best.

Thanks. Just a few days ago I was checking your 535is zinno thread. Nice work!

From what car 6 - speed tranny is used for conversion? E39?

Ha! Maytag's swap is a 5-speed, but the shift knob is from an E34 (I previously had an E34 540i M-Sport and had kept a semi-broken knob I replaced).

MInerva has a 6-speed from an E46 M3.

How much work is involved in the 6 speed swap Charlie?

[1st 5er]

Dat PDR guy has skillz.

[tig]

How much work is involved in the 6 speed swap Charlie?

LMFAO at this question. Sorry, but it's just funny because it involves ALSO swapping an S54 motor. Go read my Mineva thread.

[gwb72tii]

How much work is involved in the 6 speed swap Charlie?

LMFAO at this question. Sorry, but it's just funny because it involves ALSO swapping an S54 motor. Go read my Mineva thread.

lol

[Foonfer]

Subscribed.

If not for the amazing cross-discipline restoration skills (much respect - I am in awe), then for your black car spreading the gospel across Europe, of 16-inch Style 29 wheels on E28s!

On the E28 Sport Seat vs. "Comfort" seat dilemma - we'll have to agree to STRONGLY disagree.

At least we seem to align on the thought that the 5-spoke atrocities the car came with had to go, and I commend you for getting rid of them. Not sure if I like your replacements (bigger than 16" - hmmmm) but they are not the others.

Cheers! keep'em coming

[Rthlss1]

Subscribed.

If not for the amazing cross-discipline restoration skills (much respect - I am in awe), then for your black car spreading the gospel across Europe, of 16-inch Style 29 wheels on E28s!

On the E28 Sport Seat vs. "Comfort" seat dilemma - we'll have to agree to STRONGLY disagree.

At least we seem to align on the thought that the 5-spoke atrocities the car came with had to go, and I commend you for getting rid of them. Not sure if I like your replacements (bigger than 16" - hmmmm) but they are not the others.

Cheers! keep'em coming

Thank you

[Rthlss1]

I had filled AC last week - worked for a few hours then the AC pipe burst and let all the gas out. Good thing that I just parked the car and was able to diagnose what pipe was leaking. Removed the bastard and had the rubber hose replaced. Already mounted with new O-rings but I haven't refilled the AC yet.

20220726_202813 by Jan Podržaj, on Flickr
20220727_165756 by Jan Podržaj, on Flickr

There was some rust bubble in the rear passenger pillar corner that I had repaired and I finally picke up the filter box and wiper arm blades from the paint shop.

20220706_193006 by Jan Podržaj, on Flickr
20220722_105124 by Jan Podržaj, on Flickr
20220704_224852 by Jan Podržaj, on Flickr
20220707_195042 by Jan Podržaj, on Flickr
20220707_195622 by Jan Podržaj, on Flickr

Next on the agenda is having car detailed and ceramic coat applied since I think I am finished with mechanic work.

[Mdreamer]

Thank you for keeping us posted. I'm enjoying watching your progress.

[Rthlss1]

I have replaced the cluster plate that indicates speed and mileage to euro one. It now indicates speed in km/h and mileage in km. I have converted miles to km as well.

20220829_111852 by Jan Podržaj, on Flickr
Also I had it polished and a ceramic coat was applied.

Resized_20220918_152309 by Jan Podržaj, on Flickr
Resized_20220918_152325 by Jan Podržaj, on Flickr

[1st 5er]

I have replaced the cluster plate that indicates speed and mileage to euro one. It now indicates speed in km/h and mileage in km. I have converted miles to km as well.

That's different, as most US owners that buy euro cars maintain the cluster's euro effect.

[Rthlss1]

I have replaced the cluster plate that indicates speed and mileage to euro one. It now indicates speed in km/h and mileage in km. I have converted miles to km as well.

That's different, as most US owners that buy euro cars maintain the cluster's euro effect.

Euro ones are more desired plus its hard to see lower speed ond dual dials - 50km/h speed limit for example.

Detailing video: https://m.youtube.com/watch?v=2cno22--F ... 7gGg56UaAc