S50 Z3M Roadster Progress

Chazzy

Zorg Legend
Joined
Jul 14, 2015
Points
83
Location
Northampton
Hi,

I'm new to the forum and thought I'd share my current project.

It's a '99 Z3M roadster which I 'obtained' last summer. It used to belong to my Mum who bought it in 2004, but sadly she died in 2009. Since then it's been sat in my Dad's garage doing around 300 miles a year, with a little summer driving, and yearly servicing and MOTs. It's currently at 103k miles. He was considering getting rid of it a couple of years ago, but was given a load of crap information about the car saying it was an import and was worth next to nothing. After doing some digging, I found out it was originally registered in Northern Ireland and so had a different plate on it. It was reregistered in England in 2002, and so is not an import. Anyway, I cheekily asked my Dad last year if I could have it, and he said yes, on the condition that if I sell it, he gets the money. Fair enough.

It's not in the best condition, it's been regularly serviced but there's a long list of things wrong with it which I'm going to start working my way through. I went through all the documentation and found out some interesting items which my Dad was totally unaware of. Mainly the work done to it at West Tuning in Thruxton shortly before we bought it from Munich Legends. In there was a dyno sheet with the registration showing 354bhp.... I gave them a ring but sadly due a fire a few years ago they didn't have any information on the car. It does have a Gruppe M induction kit on it, and I wouldn't be surprised if it's been re mapped and got feisty cams in it. The plan will be to take it to a rolling road at some point to see what it's really putting out.

Anyway, the list of problems are (and growing!)...... Shocks are all knackered, bushes are all knackered, rear top mounts need replacing, seat bushes need replacing, cracks in the boot floor, crack in the rear cross beam, scuffed alloys, temperamental oil temp sensor, failed outside air temperature, worn seats, oil fill light comes on during fire up, big ding on the near side sill, scuffed alloys, scratches on the underside of the front bumper, alarm/remote lock doesn't work, various marks on the paint.......

...and it needs new tyres. It currently has Hankook V12s but I'm not convinced...!

It wasn't very nice to drive at all, Ioved the engine and having the top down, but the handling was pretty scary. It was time to get on and fix it. I took it off the road when the tax ran out in October, and have only just started working on it. (I also have a kit car which took priority at the time which needed a complete engine rebuild).

Anyway, here are some pictures, they are in chronological order and I'll add some info for each.


On the day I got it!








It definitely needed a wash, and it came out looking a little fresher:



I used it a little but didn't want to due to the handling problems so it got parked in the garage (which I painted over the winter!)





Then the work started:



I've ordered a full set of powerflex bushes, an H&R ARB kit, koni sport suspension kit, ally rear top mounts, and a racing line strut brace. It's all coming out!

Subframe out and jet washed


Boot floor - it actually looks like some work has already been done on this due to the paint and some additional welds along the back.


Crack in cross bearm and hole where the spot welds have failed


Paint taken off and then bolted together through the failed spot welds. I've seam weld this and then weld up the holes.


Cleaned up crack - the bolt on the RHS has pulled all the floor back together and in doing so helped close up the crack. I'll need to reinforce this with some sheet metal.

I started welding it all last night, and since found more horror which needs to be welded. I'll put some pictures up of this when it's finished. My ARB kit and bushes have arrived as well so the rear subframe can start going back in soon once I've given it some paint!
 

Cooper

Zorg Guru (IV)
Supporter
Australian Zeds
Joined
Apr 17, 2014
Points
157
Location
Hobart Tasmania Australia
Model of Z
3.0i 2001
Welcome. Great project - make sure you keep the receipts for all the work done so you can take it out of the sale price but I bet you won't want to sell it once you have finished! :) Good to see another zed rising from the ashes,
 

Antm72

Zorg Expert (II)
Supporter
British Zeds
Joined
May 4, 2015
Points
246
Location
South Yorkshire
Model of Z
2.8
Great project nice to have a big garage to do it in ! Looking forward to watching your progress :)
 

pgunter

Zorg Guru (V)
Supporter
British Zeds
#ZedShed
Joined
Aug 15, 2014
Points
185
Location
Winchester
Model of Z
2.2i Sport Zedshed Special
Looking good. You mentioned Thuxton.. Are you local Hampshire ?
 

Shelly

Zorg Expert (I)
Supporter
British Zeds
East Anglian Crew
Joined
Jul 9, 2013
Points
201
Location
Norfolk
Model of Z
Z4 2.0 20i M Sport sDrive
Hi and welcome from me too :p
From Bradwell near Great Yarmouth :)
Good luck with your Z ;)
Bet the end result will be fantastic :)
 

Chazzy

Zorg Legend
Joined
Jul 14, 2015
Points
83
Location
Northampton
Cheers! I'll keep this updated. I've been on the phone to the chap at CA international and he's been very helpful. My next job will be getting all the bushes out of the sub frame which will be painful. The beam bushes look a little tricky, I'll probably try and use a gear puller and fab up a U shaped bracket to push against. It'd be nice to gear the subframe back in this weekend. The shocks haven't arrived from Koni yet though.

Does anyone have any experience with the ambient temperature sensor? I've got the rear wheel arches out at the moment so have easy access to it - is it the sensor that usually fails?
 

GazHyde

Administrator
Administrator
Global Moderator
M Power
Joined
Dec 2, 2011
Points
226
Location
Berkshire
Model of Z
Z4 MR
The beam bushes look a little tricky
When my rear end was rebuilt (by Lee) the rear beam was taken to a local garage who have a 100 ton press to push them out and press the new ones in. It's way easier to outsource this particular task if you can find somewhere local.
 

Chazzy

Zorg Legend
Joined
Jul 14, 2015
Points
83
Location
Northampton
Bit of a quick update. I've done the welding although it wasn't pretty. Trying to lie on your back underneath a car with a mig welder is quite tricky! I also found there was some corrosion where the spot welds had failed so surprise surprise holes opened up as I welded it.

I've painted it with some primer, just need some blue paint to cover it up and put under body sealant underneath. Hopefully this will sort it for the moment. Luckily there weren't any signs of cracks on the diff mount which is good.

I started trying to get the beam bushes out, they are much tighter than anticipated. I welded up a U shaped section and tried with a gear puller but it all pinged off. I've got another idea which I'm going to try. They WILL come out!

As soon as I find a solution which works I'll put some photos up on here.

I've also order some seat bushes to fix the annoying movement on the drivers seat and new hand brake cables.
 

Chazzy

Zorg Legend
Joined
Jul 14, 2015
Points
83
Location
Northampton
I originally posted in the gallery section in error, so I'll continue in here where it's more relevant.

All my upgrade parts have arrived and it's nearly time to fit them. It's just a matter of removing all the bushes.....




I've started on the rear beam, I tried using a gear puller to remove the beam bushes but no luck so far. I've got another plan of attack using a twin arm bearing puller and a pitman arm puller. I'll try getting the trailing arm bushes out with some threaded bar and large sockets. I think a bit of heat might help as well!

I've got the diff out the rear beam, ready to 'de rust' it all and then paint it before reassembly and fitting.

Does anyone know where I can get the rear protection plates from? They are both very rusty and could do with replacing. http://www.online-parts.co.uk/ looks to stock them but I've never dealt with them before.
 

Lee

Zorg Guru (V)
British Zeds
M Power
#ZedShed
Joined
Mar 26, 2014
Points
193
Location
Basingstoke
Model of Z
Z4 Coupe 3.0si
You have pretty much mirrored my setup right there. Look forward to hearing how she's handles :)

If your stuck removing the old bush try running a drill down the inside in a few places then spraying WD40 in the holes. Worked for me. Now I have access to a 100ton press which takes about 20seconds.
 

GazHyde

Administrator
Administrator
Global Moderator
M Power
Joined
Dec 2, 2011
Points
226
Location
Berkshire
Model of Z
Z4 MR
I originally posted in the gallery section in error, so I'll continue in here where it's more relevant.
Using the magic of the interwebz I've merged the two threads together so you don't lose the information from the original thread.

Hope that's OK!
 
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