Bognor Lean-to Project

Mazza

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Wasn’t going to do anything today…. But remembered a little job that I should have done ages ago and had completely forgotten..

A broken stud in the nearside wheel arch!!!
7014BAA6-7529-43AA-8BE0-C375C1DF21DC.jpeg

Its the bottom stud of the wiring box….
So tool of choice
046081AA-3D20-45AB-8221-51DF01ED6DDA.jpeg

And moments later…
FD36469A-EA34-4C32-91A6-764A9B275A52.jpeg

I had noticed there was a bit of a boss around the bottom so instead of drilling out and using a threaded insert….. Found a suitable M5 screw, and appropriate size drills, and just drilled and tapped it
13E25F93-57AF-4BFB-A55A-46500A6B85AE.jpeg
Cut the head off the screw . A bit of loctite and screwed it in until it matched the length of the upper stud…


D0082DA4-8EB2-420D-AA2E-0B1AD04D88A0.jpeg

Didn’t want to strain the stud so tapped the nylon nut as well ( these normally just cut their own thread on the stud as you wind them on)
39FA4EEE-D4E6-4D86-A018-C0D74CFFB875.jpeg

And about 30 mins after I went into the garage…
CA992B94-C4B2-4C6E-A4CA-B807D8657817.jpeg


one more bit done :happy:
 

Mor61e

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Just read through this whole thread over the last few days and I take my hat off to you, fantastic work and a great read/pictures!

Really glad you’ve carried on with it after all the time and effort put in, will be a great car when finished to enjoy :cool:
 

Mazza

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No where near finished, but already getting buying add-ons :eek:

A bit of a rarity these days.........Original Genuine BMW unused front mud-flaps with fitting kit still in its sealed bag.

8834D124-9B2E-486A-82E0-EBC310F1B415.jpeg


Last week picked up a brand new Original BMW 2.8 rear box .....so just need to fill in the space between that and the downpipes at the front......=))
663F7F08-58E5-4972-8270-138309F767DA.jpeg
 

Mazza

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Just ordered the missing part of the exhaust.
They confirmed it is a direct replacement for my car… info taken from Reg number!!
Their picture shows the 2 cats, post cat threaded bosses for the two sensors, and they confirmed that it had the fixing points….
So will see when it arrives. :whistle:
but for less that £240 … worth the chance
( not stainless… but can live with that for now, and will match the rear box that I already have)
 

Mazza

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After a morning spent at a speed awareness course.....which was ok and better than the 3 points on offer:whistle:

Home in time to receive a new bit to fix on the car......

A new middle section
83C44A00-5A9E-4F8A-92A5-F43254A6AD82.jpeg


Seems to be the right shape and looks like the one that came off the car.

Front flanges already have slits in ( a Zedshed approved mod =))
BE6BC32E-1881-403E-899E-E95875423BF3.jpeg


There are two brackets .....one I assume will match up with the gearbox support
E1D34C80-C9CE-4F9A-A055-BE40F12804D1.jpeg


Two threaded bosses after the cats for the sensors
99C2676F-A8B6-4088-9BDC-E649E1DE32AE.jpeg


Comes with a connector and two U clamps to to join on to the rear box. ( which I bought recently on the forum)

5B12EE7A-F6F1-43AA-ABF1-3EED3F5BC506.jpeg


Only thing missing is a bracket that lines up the the rear beam support
Should be roughly where the aluminium strip is
AE330626-C324-49B7-80E1-B88CE7D50FE8.jpeg


And joins onto the beam bracket
BDEB6797-C318-44FF-849B-EC33918DAD4A.jpeg


Might have to get a bit creative for that!!!!:whistle:

But looks ok
One other thing that I need to sort...
Rear box Genuine BMW and for the 2.8.....and it came with two chrome tips

71F62768-9F3E-4AEE-B969-826127E3C04E.jpeg


But they are not the same shape ??????
2622969D-77DB-48B4-8927-A852400E670E.jpeg


The box has oval pipes and the tips are round ??????? And yet they were originally supplied as mating parts ???
Dont understand that.

Looking forward to getting it fitted asap.....and firing up the engine for the first time in about 2 years
 

Mazza

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Two more new parts ....
After cat lambda sensors right and left..... ( but at this point have no f***ing idea which is which =)) )

Autodoc was the cheapest. ......for Bosch........but tried my local Motor Factor where I know a couple of the guys ( musicians like me .....actually no ...they are good musicians.....) got a good discount....so a happy Bognor bunny =))

Same Bosch numbers that AutoDoc would have supplied.
ED1F6C31-156F-438F-A389-AB4FEB516D0A.jpeg


Bosch saving money on plain packaging by the look of it !!!!!!!
 

Mazza

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Just a small update as I did get underneath the car this morning (until I over stretched and pulled the muscle in my shoulder again :arghh: )

Wasn’t intending to do much more anyway other than see how the new exhaust fits.


Having crawled underneath, I am a bit concerned that over time the car has dropped on the 4 axle stands.....My belly now keeps hitting the underside of the car :whistle:

Anyway...
Bit of a struggle trying to manoeuvre that large lump of dead weight underneath the car .....but once I was under, the exhaust was easy to pull in and lift up onto axle stands=))


Front connections line up ok
6982ACC0-D6F1-45CB-BBAE-180B6A0B4FFD.jpeg


The gearbox mount lined up ....but will just need a bit of a tweak , and probably easier to bend the arm rather than the exhaust bracket.
A6ED7B10-2913-496F-B88B-858E22831218.jpeg


Must remember to remove the cardboard =))
78695DD8-C822-454B-888F-233CA56677C4.jpeg


There is a bracket missing from the exhaust, so I will have to sort out a solution which may mean taking off the beam bracket and replacing it with just a stud of some sort ( I have a cunning plan!)
95E8452C-9922-4488-AAEF-8BE4FF419435.jpeg


Overall not bad, and fits with good clearances, so not bad for just under £240.
8E31312F-C148-44D8-ACDC-EC5C85962489.jpeg


Rear Box fits correctly onto the pipe with the joining piece supplied
A781DA5E-8C90-4691-AF63-5F21A0811320.jpeg


And locates with a nice even clearance over the top
F73EDD1A-EA41-417D-A95F-6B2E89C94F91.jpeg

Life expectancy on a mild steel system is about 3-4 years ....going to try some paint, after a recommendation, and just as an experiment
The whole exhaust and any brackets will be sprayed matt black.
I dont expect it will stop it rusting ....but may slow it down a bit.

That was it for today...retired hurt , but not so much that I can’t nip down the pub :drinks:


Oh , and the threaded bosses after the two cats were correct as I tried one of the sensors to make sure. :)
 

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Mint

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Looking really good malc, you're definitely on the home stretch now:thumbsup:
 

Ian&Sue

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Just a small update as I did get underneath the car this morning (until I over stretched and pulled the muscle in my shoulder again :arghh: )

Wasn’t intending to do much more anyway other than see how the new exhaust fits.


Having crawled underneath, I am a bit concerned that over time the car has dropped on the 4 axle stands.....My belly now keeps hitting the underside of the car :whistle:

Anyway...
Bit of a struggle trying to manoeuvre that large lump of dead weight underneath the car .....but once I was under, the exhaust was easy to pull in and lift up onto axle stands=))


Front connections line up ok
View attachment 241629

The gearbox mount lined up ....but will just need a bit of a tweak , and probably easier to bend the arm rather than the exhaust bracket.
View attachment 241647

Must remember to remove the cardboard =))
View attachment 241633

There is a bracket missing from the exhaust, so I will have to sort out a solution which may mean taking off the beam bracket and replacing it with just a stud of some sort ( I have a cunning plan!)
View attachment 241637

Overall not bad, and fits with good clearances, so not bad for just under £240.
View attachment 241639

Rear Box fits correctly onto the pipe with the joining piece supplied
View attachment 241643

And locates with a nice even clearance over the top
View attachment 241645
Life expectancy on a mild steel system is about 3-4 years ....going to try some paint, after a recommendation, and just as an experiment
The whole exhaust and any brackets will be sprayed matt black.
I dont expect it will stop it rusting ....but may slow it down a bit.

That was it for today...retired hurt , but not so much that I can’t nip down the pub :drinks:


Oh , and the threaded bosses after the two cats were correct as I tried one of the sensors to make sure. :)
Not surprised that you're retired hurt after all, what you've been doing is Exaust-ing.

Ian.
 
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Mazza

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I had a plan to do bits and pieces between the footy games……
So went out to connect up all the brake hoses… needed to add a washer as the braided hoses have longer threads that std ones so there is a bit of movement.
F7D0C9B0-21BF-4645-B780-FBC14FF290AA.jpeg

Just a std M14 BZP washer


But didnt go as planned aI smacked my head on a sharp part of the car !!!
B1B49958-9981-440D-9B13-84BDFBF00232.jpeg

But medicine at hand…
EEAD200E-BE9A-4431-B887-1BAE1D3EF208.jpeg

(Aldi special !!!:whistle:)

still now only 2 to do … then bleed the system ( and not my head) :arghh:
 

t-tony

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Ouch, that’s look bloody painful Malc. When Shirl’s old dad was still working he regularly had cuts and lumps on his swede.

Tony.
 

Mazza

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Ouch, that’s look bloody painful Malc. When Shirl’s old dad was still working he regularly had cuts and lumps on his swede.

Tony.
You’d think that as you get older you would learn to not to do things like that…… no bloody chance !!!

May need to respray it hellrot red to cover up the blood spatters=))
 

t-tony

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I've been upcycling some wood this week and I got a 4ft sash cramp across my head at teatime for my trouble. Should've fitted the lower one first maybe.;)
20221124_152957.jpg

Work in progress.

Tony.
 

Mazza

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Got out in the early morning sunshine and finished off the last two connections … with no further blood loss =))
6CA8A4B7-3B23-4D68-B59B-AB0C2360E351.jpeg

A05A1590-1D92-4D2A-A57E-73851E8D8C06.jpeg


so just the bleeding to do …. The car that is, not me:arghh::whistle:

41A8FE98-B149-4C69-A6A5-931E2F76C218.jpeg


its getting there !!!!:):)
 

Mazzal

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I had a plan to do bits and pieces between the footy games……
So went out to connect up all the brake hoses… needed to add a washer as the braided hoses have longer threads that std ones so there is a bit of movement.
View attachment 242315
Just a std M14 BZP washer


But didnt go as planned aI smacked my head on a sharp part of the car !!!
View attachment 242311
But medicine at hand…
View attachment 242313
(Aldi special !!!:whistle:)

still now only 2 to do … then bleed the system ( and not my head) :arghh:
Is that litmus paper in the bottle - to tell you what % it is - 😂
 

Mazza

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Just nipped out at half time in the Qatar v Senegal game and put the brake system under test.
Used my Sealy brake bleeder (no fluid ) to put 10psi into the system
871D07E3-297D-4BD3-BCE3-5DE02CC487D1.jpeg

Check it at the end of the game :thumbsup:
 

Mazza

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Dropped a bit after an hour or so

FD86344C-4FE5-40E8-A525-033F34D1862C.jpeg


two of the caliper bleed valves were weeping (hadn’t completely tightened them :whistle:
And some brake fluid was in the pipe… which would indicate the bleed bottle wasnt fully sealed
8D76C9C1-89B6-4585-BDA2-C66A49B020D7.jpeg


So checked all the connections and they were all dry …. So pretty sure the system is ok.
Need to get some new brake fluid. I have some over from the last time so will use that to flush the system before introducing the new fluid into the system.
Might do that on Tuesday when I am expecting a visitor…. Who will be a willing volunteer…=)) ( its either this or Christmas shopping ( :arghh: ) with Maxine
 
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