This next part is the best bit. Popcorn at the ready 
Bognor Lean-to Project
- Thread starter Mazza
- Start date
If you are stuck, simply fix everything with sticky tape and consult your nearest ZedShed 
You are an inspiration Mazza. Every time I read this thread it makes me want to go into the garage & start pulling the car apart! Sue on the other hand would prefer to enjoy the car by driving it not as the pile of bits that she imagines we will be left with if she ever lets me loose on it.The rebuild started today , when I actually put some bits back onto the car
Admittedly it was only a few new fixings and parts on the on the slam plate and fixed the cooling loop back into place …..but it is a start. Oh and I also pushed in all the new wheel arch nylon body nuts.
also after an early start this morning finished the slam plate and wheel arches with a coat of Topaz Blue.
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Tomorrow I should be able to start on all the big stuff that fix, turn, spin, spring, damp, brake and locate the big round rubber things .
Gradually getting the hang of these technical terms
I have worked out ( based on the Zedshed build of about an hour per side) it should only take me about …………
10 days. ( per side)
Ian.
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Well today was a bit of a non event.... I was hoping to really get on with it but like all good ideas......it went south!
Started with finding a container with all the hub nuts and bolts.....which hadn't been cleaned and treated....
So that was the first job..
Then thought it would be a good idea to get all the parts in one place, rather than scattered around the house.
So sorted out all the front end parts into N/S and O/S
Lots of bits.....but thats when I found I still had parts missing
So. Checked on RealOem and got all the part numbers, called the local stealer and ordered a few of the bits 2 brackets for the front drop links, the nuts and bolts , and a couple of other fixings,,,,,,,bye bye to £70.00 !!!!!!!
But the front and rear ARB bushes are on a worldwide shortage and on back orders......so didnt bother.
So tried a few UK suppliers and front ones available , but no rear ones,,,,,
Checked Autodoc, and they had fronts (Febi) and rears (Moog) and also got all the ABS sensors .......another £75.00
and it will be another week before they arrive.
Sorted out the plastic trim pieces that fit around the front end, only to find a few issues, but will all be sorted with a trip to Andy’s
One thing I can do is reinstall the exhaust manifolds, and the new studs, so may do that tomorrow.
So may be able to report on some actual progress
EDIT........just looking at the pictures and realised I need the 4 jubilee clips for the track rod gaiters.......
Started with finding a container with all the hub nuts and bolts.....which hadn't been cleaned and treated....
So that was the first job..
Then thought it would be a good idea to get all the parts in one place, rather than scattered around the house.
So sorted out all the front end parts into N/S and O/S
Lots of bits.....but thats when I found I still had parts missing
So. Checked on RealOem and got all the part numbers, called the local stealer and ordered a few of the bits 2 brackets for the front drop links, the nuts and bolts , and a couple of other fixings,,,,,,,bye bye to £70.00 !!!!!!!
But the front and rear ARB bushes are on a worldwide shortage and on back orders......so didnt bother.
So tried a few UK suppliers and front ones available , but no rear ones,,,,,
Checked Autodoc, and they had fronts (Febi) and rears (Moog) and also got all the ABS sensors .......another £75.00
and it will be another week before they arrive.
Sorted out the plastic trim pieces that fit around the front end, only to find a few issues, but will all be sorted with a trip to Andy’s
One thing I can do is reinstall the exhaust manifolds, and the new studs, so may do that tomorrow.
So may be able to report on some actual progress
EDIT........just looking at the pictures and realised I need the 4 jubilee clips for the track rod gaiters.......
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I feel your pain Malc but nothing like doing a proper job.
So .....did I get the manifolds on?......no!
With all the painting and welding that has been done, the garage was covered in a thick film of dust.....so rather than keep laying in it, I thought I would have a clean....
I did look at the manifolds only to realise I had missed a bit of painting,,,,,so got that done first, while access was easy,
It was the lower part of the chassis I missed
Masked it off so I didnt have any overspray , and worked out ok
I also noticed a wiring repair on the temp sensor. Wires twisted with a covering of selotape.....FFS !!!!!!
Stripped it, cleaned, soldered, sleeved and then the taped.
Its left just hanging as I have no idea where it goes I’m sure I’ll find a hole somewhere that it fits into
Other than that I painted the fuel tank with a new camouflage paint......seems to work ok, and the tank is pretty much invisible...........
With all the painting and welding that has been done, the garage was covered in a thick film of dust.....so rather than keep laying in it, I thought I would have a clean....
I did look at the manifolds only to realise I had missed a bit of painting,,,,,so got that done first, while access was easy,
It was the lower part of the chassis I missed
Masked it off so I didnt have any overspray , and worked out ok
I also noticed a wiring repair on the temp sensor. Wires twisted with a covering of selotape.....FFS !!!!!!
Stripped it, cleaned, soldered, sleeved and then the taped.
Its left just hanging as I have no idea where it goes
I’m sure I’ll find a hole somewhere that it fits intoOther than that I painted the fuel tank with a new camouflage paint......seems to work ok, and the tank is pretty much invisible...........
Very impressed Malc 
Could do with some of that paint myself, wor lass wants the kitchen tiling.
Good spot with the temp sensor, another future problem sorted.
Good spot with the temp sensor, another future problem sorted.
After a run over to the stealer to collect some bits, ( which they forgot to put two nuts in the package )
So will mean another run over tomorrow to pick them up,.....,
So onwards and underneath.....
First part....8 studs inserted using two of the old nuts locked together
Then the gasket. ( and luckily got the stud pattern correct as there are 4 holes not used)
Then the rear manifold with new nuts and subsequently torqued up. Had to work out how to get to to them all and tighten them in a sequence from the middle out in 3 stages.
Then the same for the front one., which is easier to start them from the top, and then underneath to finish torquing.
Next bit is to route and connect the sensors, and while I am there, blank off the smog filter vacuum line at the back of the block.....but the sun is out, and I had something more important that I needed to do........
Go for a play,,,,
Anyway, too hot to be stuck in a garage......
)So will mean another run over tomorrow to pick them up,.....,
So onwards and underneath.....
First part....8 studs inserted using two of the old nuts locked together
Then the gasket. ( and luckily got the stud pattern correct as there are 4 holes not used)
Then the rear manifold with new nuts and subsequently torqued up. Had to work out how to get to to them all and tighten them in a sequence from the middle out in 3 stages.
Then the same for the front one., which is easier to start them from the top, and then underneath to finish torquing.
Next bit is to route and connect the sensors, and while I am there, blank off the smog filter vacuum line at the back of the block.....but the sun is out, and I had something more important that I needed to do........
Go for a play,,,,
Anyway, too hot to be stuck in a garage......
The project has stalled a bit over the last couple of weeks, but that was down to other commitments (ie a wedding , some work around the house, and a fair bit of running round to get all the parts to convert another 15 sets of tank straps to the Z3M version, as I have had some more requests for them)
As I now have the strut gaskets ( don’t know why they are now supplied with the top mounts?) a fuel filter, 4 new ABS sensors, and the front and rear ARB bushes, I could get on with it .......if it wasn't raining and cold
Also had a car sprayer round in the week to look at the project.....Gave me some very useful tips etc, and will also save me a lot of unnecessary work prior to it getting a respray. Front panels condemned, but the bonnet will be ok with a bit of TLC !!
Rear panels not brilliant , and one has a dent ....so I have taken the decision to find two rust free ones. Any colour!!
A trip up to Andy ( Spurs) this weekend and I now have replacement rust free front panels, an indicator light, and some trim parts.
One trim part is no longer available
The one on the right with the hole, where an air intake duct clips in. What you have to do is get the standard one, part number 51718397357, and put the hole in. This part is used on the 1.9 so lots available.
My original ( on the right) also has the two fixing point missing on the front edge.( broken off)
What I was going to do was cut all the webbing parts off, and use it as a template to get the hole located correctly, but I have found that the cut out position is actually marked on the trim panel already
I will use a hole saw to remove as much as I can then carefully file it out to the line.
As I now have the strut gaskets ( don’t know why they are now supplied with the top mounts?) a fuel filter, 4 new ABS sensors, and the front and rear ARB bushes, I could get on with it .......if it wasn't raining and cold
Also had a car sprayer round in the week to look at the project.....Gave me some very useful tips etc, and will also save me a lot of unnecessary work prior to it getting a respray. Front panels condemned, but the bonnet will be ok with a bit of TLC !!
Rear panels not brilliant , and one has a dent ....so I have taken the decision to find two rust free ones. Any colour!!
A trip up to Andy ( Spurs) this weekend and I now have replacement rust free front panels, an indicator light, and some trim parts.
One trim part is no longer available
The one on the right with the hole, where an air intake duct clips in. What you have to do is get the standard one, part number 51718397357, and put the hole in. This part is used on the 1.9 so lots available.
My original ( on the right) also has the two fixing point missing on the front edge.( broken off)
What I was going to do was cut all the webbing parts off, and use it as a template to get the hole located correctly, but I have found that the cut out position is actually marked on the trim panel already
I will use a hole saw to remove as much as I can then carefully file it out to the line.
Finally started putting bits back on today.......until I found I didn’t have the little screws that locate the front discs....oops!
So as they were in stock and only 70p each I went over and picked them up in the 1.9....and as it was sunny, came home the long way round And so didnt get much done
Still its a start...
Oh and after forgetting to buy it.....bloody forgot to fit it.......
It is in place now !!!!!
I was a bit concerned at the length of the studs through the turret, as if I had forgotten a spacer or someting , but I think its just that Ridex top mounts use longer studs......maybe allowing for a strut brace???
Bearing is a tight fit, but found a socket that fitted on the bearing race ( as it says in the book) and tapped it on to the shaft until there was enough thread to use the nut to wind it on. Seated ok .
This was the point when I found I didnt have the disc bolt.....
So much later on.......
The jack is only taking some of the weight as I dont like it just hanging in mid air......and the disc isnt red , its the reflection of my sleep mat ...I mean work mat.
I have torqued up most of the bolts as I have been doing it, but, the hub nut is a massive torque and if I tried it I would probably have the car drop off the axle stands on to the floor.....so that can be done later.....
To that end I have created a list of ‘ Nuts that need Attention’. So I dont forget any ....
Funny thing is , and for some reason, I put @pgunter at the top of the list......
I must admit , with everything either new or cleaned, it does go together easily.
So as they were in stock and only 70p each I went over and picked them up in the 1.9....and as it was sunny, came home the long way round
And so didnt get much doneStill its a start...
Oh and after forgetting to buy it.....bloody forgot to fit it.......
It is in place now !!!!!
I was a bit concerned at the length of the studs through the turret, as if I had forgotten a spacer or someting , but I think its just that Ridex top mounts use longer studs......maybe allowing for a strut brace???
Bearing is a tight fit, but found a socket that fitted on the bearing race ( as it says in the book) and tapped it on to the shaft until there was enough thread to use the nut to wind it on. Seated ok .
This was the point when I found I didnt have the disc bolt.....
So much later on.......
The jack is only taking some of the weight as I dont like it just hanging in mid air......and the disc isnt red , its the reflection of my sleep mat ...I mean work mat.
I have torqued up most of the bolts as I have been doing it, but, the hub nut is a massive torque and if I tried it I would probably have the car drop off the axle stands on to the floor.....so that can be done later.....
To that end I have created a list of ‘ Nuts that need Attention’. So I dont forget any ....
Funny thing is , and for some reason, I put @pgunter at the top of the list......
I must admit , with everything either new or cleaned, it does go together easily.
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Got on with the other side this morning,
All going well ….
then a disaster!!!!
Could have kept this mishap quiet, but decided to write about this to stop anyone else having the same problem.
I put the rear dust seal on the shaft, and then tapped the bearing on ( as I did on the other side) until I could get the nut on to tighten it all up, but unfortunately the dust seal must have dropped down so the hub would not locate correctly.
I had to pull the hub off with a puller, but it left the inner bearing shell on the shaft, and I could see the seal damaged and out of line
Fortunately the puller I have is a universal one so made it into a two jaw and got enough on the bearing shell to remove it.
And then get the dust seal off.
Dust seal bu**ered, so will replace it. Not sure about the bearing seal, but don’t know if they are obtainable as a separate part as RealOem only shows the hub as a complete unit.
The bearing faces etc are ok and after putting a bit more grease in, the bearing race is fine.
oh well, sh*t happens
All going well ….
then a disaster!!!!
Could have kept this mishap quiet
, but decided to write about this to stop anyone else having the same problem.I put the rear dust seal on the shaft, and then tapped the bearing on ( as I did on the other side) until I could get the nut on to tighten it all up, but unfortunately the dust seal must have dropped down so the hub would not locate correctly.
I had to pull the hub off with a puller, but it left the inner bearing shell on the shaft, and I could see the seal damaged and out of line
Fortunately the puller I have is a universal one so made it into a two jaw and got enough on the bearing shell to remove it.
And then get the dust seal off.
Dust seal bu**ered, so will replace it. Not sure about the bearing seal, but don’t know if they are obtainable as a separate part as RealOem only shows the hub as a complete unit.
The bearing faces etc are ok and after putting a bit more grease in, the bearing race is fine.
oh well, sh*t happens
Should be able to buy the hub seal separately Malc.
Tony.
Tony.
BMW don’t supply it , but I could try a bearing supplier
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Does this look like it mate? Gives you the dimensions.
Tony.
A minor success this morning......managed to cut the hole for the air duct. And as fortune would have it I had a hole saw exactly the right size 
. Took a bit of time to find the exact centre as its not a flat surface where the hole goes, but set it up on some wood on my pillar drill and got it done in one go.
The one on the right is the damaged one ( fixing points at the bottom have broken off) so going in the bin.
And the duct fits perfectly.
Haven’t pushed it home completely so it clips in yet, just in case it’s easier to assemble them separately later.
At last something has gone right!
Chucking it down with rain here today , so cant work in the garage with the door open. So instead I think a general tidy up, put everything away and start again once I have the replacement dust cover.
Somewhere in the garage there is some vacuum tubing, if I can find it, as there are some that need replacing at the back of the engine. Found them when installing a blanking plug to the smog valve spigot on the engine.
. Took a bit of time to find the exact centre as its not a flat surface where the hole goes, but set it up on some wood on my pillar drill and got it done in one go.The one on the right is the damaged one ( fixing points at the bottom have broken off) so going in the bin.
And the duct fits perfectly.
Haven’t pushed it home completely so it clips in yet, just in case it’s easier to assemble them separately later.
At last something has gone right!
Chucking it down with rain here today , so cant work in the garage with the door open. So instead I think a general tidy up, put everything away and start again once I have the replacement dust cover.
Somewhere in the garage there is some vacuum tubing, if I can find it, as there are some that need replacing at the back of the engine. Found them when installing a blanking plug to the smog valve spigot on the engine.
Pillar drill is a versatile tool mate. A sanding drum mounted in the chuck can be real handy too.
Tony.
Tony.
I think I need some help ,,, as I am a bit confused.......
Just been looking at RealOem,
I have removed the smog pump, and capped it using a blanking version of Number 2 ( from Tony), and then needed to remove the vacuum pipe and cap it.......
If this is now disconnected, are numbers 5 , 6 , and 7 also redundant (and could be removed?) if blanking piece number 9 is installed ??
Really difficult to see the actual parts as the wiring tray above it obscures the back of the engine.
It was the two tubes ( number 7 ) that are perished, which I though needed to be replaced, but having looked at the diagram, I am not sure if I actually require them.
Part number 5 is an electric valve , so could it be disconnected??
Hopefully someone thats done this can tell me.
Cheers
Just been looking at RealOem,
I have removed the smog pump, and capped it using a blanking version of Number 2 ( from Tony), and then needed to remove the vacuum pipe and cap it.......
If this is now disconnected, are numbers 5 , 6 , and 7 also redundant (and could be removed?) if blanking piece number 9 is installed ??
Really difficult to see the actual parts as the wiring tray above it obscures the back of the engine.
It was the two tubes ( number 7 ) that are perished, which I though needed to be replaced, but having looked at the diagram, I am not sure if I actually require them.
Part number 5 is an electric valve , so could it be disconnected??
Hopefully someone thats done this can tell me.
Cheers
Yes those parts are redundant Malc. I left them on because I didn't need to get under the manifold for any other reason. Car will run fine as long as you stop any vacuum leaks.
Tony.
Tony.
I have now come to fully understand the term “Project Car”…….it means you can do nothing for weeks on end and not feel guilty about it just sitting in the garage
My other hobby as a Rockstar Superstar has got in the way a bit after recently doing a couple of gigs….. the first for 25 years…..but so much fun and got some really nice feedback that I would like a few more while I still can……
Really crap getting old ain’t it
My other hobby as a Rockstar Superstar
has got in the way a bit after recently doing a couple of gigs….. the first for 25 years…..but so much fun and got some really nice feedback that I would like a few more while I still can……Really crap getting old ain’t it