Bognor Lean-to Project
- Thread starter Mazza
- Start date
Haven’t put the beam in yet as was expecting the first few tank straps so I could check out the fit on my car…. But not had a message to say they are ready yet 
so today connected the battery and wired up the radio….
worked with a usb stick … but not the tuner, until I realised its s DAB radio and I dont have the right aerial… Cant get it on FM??
and yes I listen to ABBA
After sorting out the speaker wiring,
I got the door rebuilt on the passenger side and hopefully the drivers one will be a bit quicker
I also plugged in my code reader and cleared the fault codes
see how many return when I finally start it.
so today connected the battery and wired up the radio….
worked with a usb stick … but not the tuner, until I realised its s DAB radio and I dont have the right aerial… Cant get it on FM??
and yes I listen to ABBA
After sorting out the speaker wiring,
I got the door rebuilt on the passenger side and hopefully the drivers one will be a bit quicker
I also plugged in my code reader and cleared the fault codes
see how many return when I finally start it.
Spent about an hour in the garage this morning and got the other door done.
Connected the battery… windows working, mirrors working…. So all good
Connected the battery… windows working, mirrors working…. So all good
Are you going to host a celebration Shed BBQ when the wheels hit the ground and she starts
Found the FM stations on the radio this afternoon…. Pays to read a manual (Found it on line)
But I noticed that the round clock/computer on the dashboard was ticking when the ignition is on and even carries on after the key is out.
Only stopped when disconnected the battery again. Nothing lights up on the display either ??? Anyone have any ideas on this??
I’m sure it used to light up when I was testing some of the boot wiring ??
(Found it on line)But I noticed that the round clock/computer on the dashboard was ticking when the ignition is on and even carries on after the key is out.
Only stopped when disconnected the battery again. Nothing lights up on the display either ??? Anyone have any ideas on this??
I’m sure it used to light up when I was testing some of the boot wiring ??
A step forward today …. Had a call to say first of the production batch of straps were done ( bent up that is) so went round to pick one of them up…
No studs in yet so just bolted them together
And look pretty good
Pulled the axle unit out to get underneath and fitted them with some rubber cushion
Happy with that
So all good
Should have 20 sets ready next week, and the Z3M modified version by the end of sept
Sorry its taken a while.
As for the project…. Just need to reinstall this lump…
I wonder if the Zedshed boys would like a weekend in Butlins???
No studs in yet so just bolted them together
And look pretty good
Pulled the axle unit out to get underneath and fitted them with some rubber cushion
Happy with that
So all good
Should have 20 sets ready next week, and the Z3M modified version by the end of sept
Sorry its taken a while.
As for the project…. Just need to reinstall this lump…
I wonder if the Zedshed boys would like a weekend in Butlins???
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As no one likes Butlins… and cant blame them.. got on with the re assembly today…
From this starting postion… to this…
1 hour 13 mins!!!!
crap by Zedshed standards, but on my own , 3 trolley jacks and had to keep checking the prop shaft was meshing with the diff as I lifted it … not too bad.
All the underside bolted , torqued and connected…so on to the next bit !!!!
You have heard of a Love Train, Drive Train and the Soul Train…. Here’s another…an exhaust train
choo choo
Just pushed under the car into position … so simple ( like me)
Transfer it onto axle stands and bolt it in … ‘simples’
Had enough for today so might sort this tomorrow ( if I dont go fishing )
From this starting postion… to this…
1 hour 13 mins!!!!
crap by Zedshed standards, but on my own , 3 trolley jacks and had to keep checking the prop shaft was meshing with the diff as I lifted it … not too bad.
All the underside bolted , torqued and connected…so on to the next bit !!!!
You have heard of a Love Train, Drive Train and the Soul Train…. Here’s another…an exhaust train
choo choo
Just pushed under the car into position … so simple ( like me)
Transfer it onto axle stands and bolt it in … ‘simples’
Had enough for today so might sort this tomorrow ( if I dont go fishing )
Go fishing mate, and take a few beers.As no one likes Butlins… and cant blame them.. got on with the re assembly today…
View attachment 277009
From this starting postion… to this…
View attachment 277011
1 hour 13 mins!!!!
crap by Zedshed standards, but on my own , 3 trolley jacks and had to keep checking the prop shaft was meshing with the diff as I lifted it … not too bad.
All the underside bolted , torqued and connected…so on to the next bit !!!!
You have heard of a Love Train, Drive Train and the Soul Train…. Here an exhaust train
choo choo
View attachment 277013
Just pushed under the car into position … so simple ( like me)
Transfer it onto axle stands and bolt it in … ‘simples’
Had enough for today so might sort this tomorrow ( if I dont go fishing )
Tony.
- Joined
- Nov 25, 2012
- Points
- 178
- Location
- Newport, South Wales,UK
- Model of Z
- Z3 M43 1.8 (1999) and Z4 E85 2.5 (2003)
You deserve a day off after doing that on your own, tight lines.
Saturday 7.30ish… and exhaust is in
That’ll do
still got about 4 nuts at the manifold flange to tighten up but you have to be a contortionist to get to 3 of them…..
So a tea break first !!
Then just two sensor leads and reattach the crossbeam and thats it for the day….
That’ll do
still got about 4 nuts at the manifold flange to tighten up but you have to be a contortionist to get to 3 of them…..
So a tea break first !!
Then just two sensor leads and reattach the crossbeam and thats it for the day….
Needs a polish MalcSaturday 7.30ish… and exhaust is in
View attachment 277089
That’ll do
still got about 4 nuts at the manifold flange to tighten up but you have to be a contortionist to get to 3 of them…..
So a tea break first !!
Then just two sensor leads and reattach the crossbeam and thats it for the day….
Started at 7.30 this morning to do two simple jobs and worked really hard until 12.00 and not any further foward
This car is a real test of my patience
So first job….
Now the exhaust is in , might as well put the front o/s wheel arch liner back in
About six screws and a couple of nylon nuts..
About 10 minutes…. ?? It was, till one of the inserts ( that I put in to replace the two studs underneath that had snapped off), got cross threaded and ended up loose in the hole.
I was originally going to put studs back in, so decided it would be better.
Because the insert was able to turn, I couldn’t drill if out so used a dremel with a small grindstone and eventually it fell inside the car.
Its in the footwell under the carpet …. And it can stay there!!!!
The hole was a bit oversize so used an M6 insert, the other one is M5
Got the new insert fitted , and cut down two screws to use as studding and after a bit of measuring to make sure the studs were long enough loctite applied and put them in place….All this activity had an adverse effect on the paintwork in that area, so couldn’t leave it…
Primer coat applied…
Followed by a topcoat…
and once dried removed the masking tape from the studs…
Yes i know no one will ever see it… but it just had to be done properly
And so, not to put undue stress on the two studs, I tapped the two new nylon nuts
one M5 and one M6
Still not put the arch liner in yet as leaving it overnight for the loctite to harden…
and so onto the other simple job…..
Replace all the door trims
so found all the trim pieces and then went searching for the fixings….
The fixings that hold each threshold is strange
RealOem calls for 6 black ones and 1 white one for each side. Different part numbers and only difference is the White one is 14.1mm and the black one is 14.85mm ???
with what fixings I had, one trim has the 6+1 but the other one has 7 white ones
I am sure it will work ok ……at least it would have done if I hadn’t found another problem
This is where the single white one should go
One half of the clip retainer is missing
So only way to sort would be another threshold……. Until I had a cunning plan
This is the strip that goes at the back of the door opening. I do have a pair loaded with the fixings, but this is a damaged one. So nothing to lose except a bit of time…..
So cut out one of the anchor points.
And put it next to the good one
A bit high.,,,
Dremel and flat file later….
Nearly there….
and finally gorilla glue and a G clamp
Leaving that to set ( overnight just to make sure) and hopefully it will fix it.
Went out this morning with all good intentions
But even after lots of effort…. still nothing got assembled.
This car is a real test of my patience
So first job….
Now the exhaust is in , might as well put the front o/s wheel arch liner back in
About six screws and a couple of nylon nuts..
About 10 minutes…. ?? It was, till one of the inserts ( that I put in to replace the two studs underneath that had snapped off), got cross threaded and ended up loose in the hole.
I was originally going to put studs back in, so decided it would be better.
Because the insert was able to turn, I couldn’t drill if out so used a dremel with a small grindstone and eventually it fell inside the car.
Its in the footwell under the carpet …. And it can stay there!!!!
The hole was a bit oversize so used an M6 insert, the other one is M5
Got the new insert fitted , and cut down two screws to use as studding and after a bit of measuring to make sure the studs were long enough loctite applied and put them in place….All this activity had an adverse effect on the paintwork in that area, so couldn’t leave it…
Primer coat applied…
Followed by a topcoat…
and once dried removed the masking tape from the studs…
Yes i know no one will ever see it… but it just had to be done properly
And so, not to put undue stress on the two studs, I tapped the two new nylon nuts
one M5 and one M6
Still not put the arch liner in yet as leaving it overnight for the loctite to harden…
and so onto the other simple job…..
Replace all the door trims
so found all the trim pieces and then went searching for the fixings….
The fixings that hold each threshold is strange
RealOem calls for 6 black ones and 1 white one for each side. Different part numbers and only difference is the White one is 14.1mm and the black one is 14.85mm ???
with what fixings I had, one trim has the 6+1 but the other one has 7 white ones
I am sure it will work ok ……at least it would have done if I hadn’t found another problem
This is where the single white one should go
One half of the clip retainer is missing
So only way to sort would be another threshold……. Until I had a cunning plan
This is the strip that goes at the back of the door opening. I do have a pair loaded with the fixings, but this is a damaged one. So nothing to lose except a bit of time…..
So cut out one of the anchor points.
And put it next to the good one
A bit high.,,,
Dremel and flat file later….
Nearly there….
and finally gorilla glue and a G clamp
Leaving that to set ( overnight just to make sure) and hopefully it will fix it.
Went out this morning with all good intentions
But even after lots of effort…. still nothing got assembled.
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Keeps the old grey matter turning over though Malc. I like watching how ingenious we can be to solve problems mate.
Tony.
Tony.
Another early start this morning….7am
And its raining… so cant have the door open !
wheel arch liner installed… and
two new studs are fine.
and the other fix….all good
I did clean some of the surplus glue off with a small file . It bubbles up a bit during the curing process…
But it worked !!
and so cut off the other good one from the donor piece…. You never know !!
so just then carefully fitted back the trim
all nice and tidy again….
and on to putting other bits back
Power Steering reservoir brkt.
There was also an addition bracket when I removed it.
fixed to the clamp bolt
But as it was not connected to anything else I have left it off . Would like to know what its for though !!?
Then cleaned the air box and surprisingly the filter inside was clean.
And installed
bottom right just above the slam plate bolts is a rubber buffer…..but on the other side
just a hole ….Luckily I have a tin of random fixings and bits…
and ….voila
On a roll now, and the rain had stopped so on to the next part….
Front Bumper… been sitting outside for two years getting covered in Courgette leaves every year!!
Turns out after bit of a wash that it is not original as its Boston Green with Topaz respray!!
This bit is usually held in by a dozen or so clips… it had just 6 and they were crap so cut them off with a stanley knife and removed thus lump for a wire brushing.
Other than needing a clean ….its ok
The cover needs a lot more attention.
Split on one end , scuffs underneath, and paint/filler coming away
So will need some TLC
The panel that is fixed to the rear of the cover is held in on plastic nibs with star washers
I am amazed at how many of these have survived.. Those that have broken off will be carefully drilled and a thin self tapper will be used.
I do have a panel
Just a bloody shame its off a prefacelift…and doesn't fit
fits like a pea in a bucket !!!!
I will now have to check RealOem as I need every fixing for the assembly after it has been fully refurbished….
I will spray it myself as I have already done other bits on the car and I will have the only Z3 in the UK with a new bespoke colour…. which I will call …… TOPAZ SHADES
and the last thing today….
put the rear number plate back on..
The front one is delaminated….
So will get a new one
and the last picture….
This is All I have left
so light at the end of the tunnel
And its raining… so cant have the door open !
wheel arch liner installed… and
two new studs are fine.
and the other fix….all good
I did clean some of the surplus glue off with a small file . It bubbles up a bit during the curing process…
But it worked !!
and so cut off the other good one from the donor piece…. You never know !!
so just then carefully fitted back the trim
all nice and tidy again….
and on to putting other bits back
Power Steering reservoir brkt.
There was also an addition bracket when I removed it.
fixed to the clamp bolt
But as it was not connected to anything else I have left it off . Would like to know what its for though !!?
Then cleaned the air box and surprisingly the filter inside was clean.
And installed
bottom right just above the slam plate bolts is a rubber buffer…..but on the other side
just a hole ….Luckily I have a tin of random fixings and bits…
and ….voila
On a roll now, and the rain had stopped so on to the next part….
Front Bumper… been sitting outside for two years getting covered in Courgette leaves every year!!
Turns out after bit of a wash that it is not original as its Boston Green with Topaz respray!!
This bit is usually held in by a dozen or so clips… it had just 6 and they were crap so cut them off with a stanley knife and removed thus lump for a wire brushing.
Other than needing a clean ….its ok
The cover needs a lot more attention.
Split on one end , scuffs underneath, and paint/filler coming away
So will need some TLC
The panel that is fixed to the rear of the cover is held in on plastic nibs with star washers
I am amazed at how many of these have survived.. Those that have broken off will be carefully drilled and a thin self tapper will be used.
I do have a panel
Just a bloody shame its off a prefacelift…and doesn't fit
fits like a pea in a bucket !!!!
I will now have to check RealOem as I need every fixing for the assembly after it has been fully refurbished….
I will spray it myself as I have already done other bits on the car and I will have the only Z3 in the UK with a new bespoke colour…. which I will call …… TOPAZ SHADES
and the last thing today….
put the rear number plate back on..
The front one is delaminated….
So will get a new one
and the last picture….
This is All I have left
so light at the end of the tunnel
Hasn't Andy got a selection of front bumpers Malc. Maybe one which is a better starting point?
Tony.
Tony.
good point might be worth a text to see …,
Unfortunately the only one that Andy had is currently in transit to Espana!!
So I will repair the one I have, and after a bit of work this morning, found out it is not too bad.
Started on the Ali part first…wire brushes and an angle grinder
Pretty Grotty
But did come off fairly easily
And after about 15 minutes….
That will do for another 24 years…
And just to prove I dont farm this work out
I did remove the two fixing bolts and noticed that one was slightly bent….
So found some nuts….
set it up in the vice…. As when its screwed up and down, you can identify which way the bend is….
Then is just a case of persuading it to be straight again….”
The Plastic part has damage but mostly underneath.
Its had a previous repair which was awful!!
Ground it down…
washed it down with a scourer and water
Came up reasonably ok, but will need a rub down all over with wet and dry to get a decent key . The split is not a problem now as I found out last night that my son has a bit of kit that repairs cracks in plastic. Heats a corregated repair plate and it pushes in across the crack to hold it together. Just means a weekend in Norfolk… so take the fishing gear
A bit of filler and paint , will be good as new
So I will repair the one I have, and after a bit of work this morning, found out it is not too bad.
Started on the Ali part first…wire brushes and an angle grinder
Pretty Grotty
But did come off fairly easily
And after about 15 minutes….
That will do for another 24 years…
And just to prove I dont farm this work out
I did remove the two fixing bolts and noticed that one was slightly bent….
So found some nuts….
set it up in the vice…. As when its screwed up and down, you can identify which way the bend is….
Then is just a case of persuading it to be straight again….”
The Plastic part has damage but mostly underneath.
Its had a previous repair which was awful!!
Ground it down…
washed it down with a scourer and water
Came up reasonably ok, but will need a rub down all over with wet and dry to get a decent key . The split is not a problem now as I found out last night that my son has a bit of kit that repairs cracks in plastic. Heats a corregated repair plate and it pushes in across the crack to hold it together. Just means a weekend in Norfolk… so take the fishing gear
A bit of filler and paint , will be good as new
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Just want to get it back on its wheels before I start it….
Then turn it round to give me better access to the front of the car