Yes you must be getting close to the finishing line now Mazza, it will be a lovley car when done.
I'd be buzzing
I'd be buzzing
Bognor Lean-to Project
- Thread starter Mazza
- Start date
Still a fair bit to do… but its moving forward 
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!!!
Its the bottom stud of the wiring box….
So tool of choice
And moments later…
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
Cut the head off the screw . A bit of loctite and screwed it in until it matched the length of the upper stud…
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)
And about 30 mins after I went into the garage…
one more bit done
A broken stud in the nearside wheel arch!!!
Its the bottom stud of the wiring box….
So tool of choice
And moments later…
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
Cut the head off the screw . A bit of loctite and screwed it in until it matched the length of the upper stud…
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)
And about 30 mins after I went into the garage…
one more bit done
- Joined
- Dec 20, 2016
- Points
- 94
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
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
No where near finished, but already getting buying add-ons 
A bit of a rarity these days.........Original Genuine BMW unused front mud-flaps with fitting kit still in its sealed bag.
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......
A bit of a rarity these days.........Original Genuine BMW unused front mud-flaps with fitting kit still in its sealed bag.
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......
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.
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)
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.
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)
After a morning spent at a speed awareness course.....which was ok and better than the 3 points on offer
Home in time to receive a new bit to fix on the car......
A new middle section
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
There are two brackets .....one I assume will match up with the gearbox support
Two threaded bosses after the cats for the sensors
Comes with a connector and two U clamps to to join on to the rear box. ( which I bought recently on the forum)
Only thing missing is a bracket that lines up the the rear beam support
Should be roughly where the aluminium strip is
And joins onto the beam bracket
Might have to get a bit creative for that!!!!
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
But they are not the same shape ??????
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
Home in time to receive a new bit to fix on the car......
A new middle section
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
There are two brackets .....one I assume will match up with the gearbox support
Two threaded bosses after the cats for the sensors
Comes with a connector and two U clamps to to join on to the rear box. ( which I bought recently on the forum)
Only thing missing is a bracket that lines up the the rear beam support
Should be roughly where the aluminium strip is
And joins onto the beam bracket
Might have to get a bit creative for that!!!!
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
But they are not the same shape ??????
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
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.
Bosch saving money on plain packaging by the look of it !!!!!!!
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.
Bosch saving money on plain packaging by the look of it !!!!!!!
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 
)
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
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
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.
Must remember to remove the cardboard
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!)
Overall not bad, and fits with good clearances, so not bad for just under £240.
Rear Box fits correctly onto the pipe with the joining piece supplied
And locates with a nice even clearance over the top
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
Oh , and the threaded bosses after the two cats were correct as I tried one of the sensors to make sure.
)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
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
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.
Must remember to remove the cardboard
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!)
Overall not bad, and fits with good clearances, so not bad for just under £240.
Rear Box fits correctly onto the pipe with the joining piece supplied
And locates with a nice even clearance over the top
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
Oh , and the threaded bosses after the two cats were correct as I tried one of the sensors to make sure.
Attachments
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Not surprised that you're retired hurt after all, what you've been doing is Exaust-ing.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
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
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
Oh , and the threaded bosses after the two cats were correct as I tried one of the sensors to make sure.
Ian.
Last edited:
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.
Just a std M14 BZP washer
But didnt go as planned aI smacked my head on a sharp part of the car !!!
But medicine at hand…
(Aldi special !!!)
still now only 2 to do … then bleed the system ( and not my head)
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.
Just a std M14 BZP washer
But didnt go as planned aI smacked my head on a sharp part of the car !!!
But medicine at hand…
(Aldi special !!!
)still now only 2 to do … then bleed the system ( and not my head)
Hope a 'wee dram' made your head feel better.
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.
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
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.
Work in progress.
Tony.
Work in progress.
Tony.
Got out in the early morning sunshine and finished off the last two connections … with no further blood loss
so just the bleeding to do …. The car that is, not me
its getting there !!!!
so just the bleeding to do …. The car that is, not me
its getting there !!!!
Is that litmus paper in the bottle - to tell you what % it is -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 !!!
still now only 2 to do … then bleed the system ( and not my head)
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
Check it at the end of the game
Used my Sealy brake bleeder (no fluid ) to put 10psi into the system
Check it at the end of the game
Dropped a bit after an hour or so
two of the caliper bleed valves were weeping (hadn’t completely tightened them
And some brake fluid was in the pipe… which would indicate the bleed bottle wasnt fully sealed
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 ( ) with Maxine
two of the caliper bleed valves were weeping (hadn’t completely tightened them
And some brake fluid was in the pipe… which would indicate the bleed bottle wasnt fully sealed
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 ( ) with Maxine