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E28 525e project

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While my M535i has been in the restoration stage for a few years, i have missed driving an E28. So when a suitable 'daily' came up, i bought it and here is the progress,




On the way home, she ran fine, no over heating etc. The previous owner replaced all or most of the steering components so the drive was tight and no wobbles.

On closer inspection only a few things need attention :

. A rust scab on the bonnet - -completed

. Bubbles in the sunroof and sunroof didn't open  - completed

. Rust on the bottom of the drivers side door - completed

. A new rubber boot needed to the AFM - completed

. Sound proofing to the underside of the carpets- waiting for spring (parts sourced) - completed

. Noisy heater blower - waiting for spring

. Removal of a large enclosed amplifier in the boot - completed


First, was to change the AFM boot over



Then address the drivers door,



An off-side replacement window guide was sourced, to replace a perished and broken guide, lifting mechanisms greased and sound deadening material placed inside the door. the vapour barrier was also replaced.

When i took the drivers side door card off, it had suffered with water damage, so i made a new one and covered it with sound insulation




The headlights were cleaned, upgraded the bulbs, replaced old components,  de-rusted the headlight surrounds and painted them with Por-15



The cylinder head looked a bit tatty, so i sourced a replacement from Tim, which was already painted. It just needed sanding in a few places. A new gasket was fitted which came with the car.




I inspected the fog lights, and no surprises there. So i ordered a new light, and painted it with Por-15 so it will not rust again. I covered the fog lights with yellow film to protect them from stone chips, to see how it looked. I haven't decided whether i like it that way yet. It's only film, so i can take it off should i decide. I preferred clear fogs in the end, so were covered with clear laminex film to protect from stone chips.




Having a look underneath i took the rear anti roll bar off, de-rusted it, painted it with Por-15, changed the anti roll bar links, changed the anti roll bar bushings and brackets. I also changed and painted the two new push rods.



I attempted to take off the front arb bracket, the rusted screw sheared off. The garage sorted that out and replaced the front arb bushings and brackets. Also replaced both front brake pipes as they were both perished. Both new front and rear brackets were spares and have been powder coated


The cover lid was cleaned and painted. The gasket however had seen better days. NLA from BMW, i made one out of cork. When i removed the Amp from the boot, it was secured by wooden batton's. A clean up revealed a small areas of rust that needed attention.


Rusty areas were sanded down, treated for rust and the whole boot painted with Por-15. The sound insulation material in the boot was missing, so i made one out of an off cut of flooring vinyl and  3mm sound  deadener. It turned out really well and looks the part. The rear light gasket seals were also replaced, as the previous owner commented the boot would get damp sometimes. New foam on the boot tool kit, a few tools replaced in the tool kit , a replacement alloy wheel to fill the empty wheel well  and the rear light trim surround sourced and replaced. The rear lights were also sanded and repainted. An electric ariel fitted and a matching spare wheel added as well.

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By now, you can guess i hate rust and the next rusty thing were the horns and a new radiator support. I tried at first with stuff from Halfords, but later tried some rust remover from Frosts, which is amazing. The headlight grills were also sanded, primed and painted



The condition of the underside of the bonnet was only dirty, with surface rust in a few places. The bonnet vents were in good order, unlike the condition on my M535i. I thought i would paint that myself and get the scab on the outside of the bonnet done professionally at a later date.

On a visit to Tim, i had seen the sound insulation material that goes across the bonnet, as opposed to the three pieces have for my other E28. Tim said he had one, so i dyed it black and it looks new now. One of the bonnet struts had failed, so i ordered and fitted two replacements. LED lights were added to the interior and the boot light. All the bulbs for the instruments, behind the dash have been replaced.



The sunroof suffered from small areas of rust bubbling through the paint work, would not open without force and the seals had perished, so i took it out and had a look. Rust had taken hold in the common areas.


The glue preventing the material on the underside of the sunroof sagging had perished and dried, so i took it off and reapplied some fresh fabric glue. It was sent to the painters and came back looking like a new one, with a perfect colour match.




My drivers side seat belt buckle was faulty, so i replaced it. While the seat was out i removed the other and replaced the underfloor soundproofing and replaced, one of the underfloor heating ducts.





Edited by Semkehead

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My car has returned from the bodyshop, where a bonnet scab was repaired and the bonnet painted and i am very pleased with the result.


The power steering fluid was changed, which was still red, but needed changing. Brake fluid checked and topped up, <1%, air filter changed, coolant changed, new window wipers.

Edited by Semkehead

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The car failed an MOT on welding, so it has been sent to Classicbahnstormers for  repairs, ready for its new owner. Thanks to Frank Mazzotta, A1 vehicle transport, for travelling so far to collect the car. The car was so reliable , it's a bit sad to see her go.

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