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Uber Soldat

E34 Touring - 525i to 540i 6 speed

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Another wagon build thread.

 

Have wanted one for quite some time. According to some I have spoken to down here, there are only around 26 in the country. Not sure how true that is, but they're pretty darn scarce. We only ever got 525i autos as far as I can tell.

 

So...found the below. Unfortunately it was put into a wall. A friend had bought it for parts, to restore his.

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After taking the front bits off...yeah, quite bad.

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Got some quotes to do the repair, good thing I was sitting down. Around a month later, while talking to the previous owner of this here touring, he mentioned that he knew of another abandoned project...

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Brought it home too:

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Stripped out the interior to find that 80% of the wiring harness had been cut out.

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Stripped out the entire harness out of the other touring and put it in this one.

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Yeah...needing some throwing star covers.

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Dyed the carpeting and seats black.

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The plan all along was to swap in a V8. So found a parts car.

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Transferring some brackets.
At one stage it had a complete M5 drivetrain.

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Wiring harness is mostly in:

018qzkq1.jpg

019imj6j.jpg

Edited by Uber Soldat

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Welcome to the forums @Uber Soldat

 

A cracking entry into these pages ;) 

 

Update your profile to show where abouts in the world you are; so it appears here:

 

<<<<<<<<<<<<<<<<<<<<<<<<<<<

 

Update your garage too; so we can see what car(s) it is you have :mrgreen:

 

Looking forward to more updates 8) 

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Installed the fuel return line. V8 cars have this running down the right hand side whereas the inline 6 cars, the line runs down the left hand side.

Strangely enough, the attachment points for the brackets that hold the line in place were already on the touring.

020skkt4.jpg
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The rear seat had some pretty rubbish leather. Managed to get some grey leather off a seat in Latvia, swapped it and dyed it black. (Thanks Tom and Benji :) )

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Had to cut some holes in order to run the V8 fuel and brake lines. The inline 6 cars have the lines run on the inside of the left fender rail. If they stayed there with the V8 in place...much boiling will take place. The V8 cars have them running on the outside and through the body as seen below:

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Removed the autofail and engine from the donor car.

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The rear subframe will need to be swapped as well.

 

Touring:
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Donor:
032n4kz6.jpg

 

Sanded the engine bay and prepped it for paint.
033rrkty.jpg
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Rear seats looking good.
035z9jpq.jpg

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Engine bay primed:
036e4jak.jpg
037uijle.jpg

 

There was a section of metal that had to be removed here as well.
038a9jtb.jpg

 

And the bay is sprayed:
039n7kc9.jpg
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We added some hinges to the tool kit holder thingy. 
0416ajvm.jpg
042gkk5a.jpg

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Added some sound deadening and heat shielding:
0433ckla.jpg

 

Brake master cylinder and ABS unit installed:
044eykp2.jpg
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Aircon compressors stuffs:
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Steering box and lines:
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Not entirely sure what this thing does. Apparently its some sort of sensor for the HVAC system:
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Some front end stuff added:
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Installed the front fuse box and associated wiring:
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Couldn't quite decide on a colour...
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Ready for a carpet:
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And carpet is in...
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Rear sedan door cards trimmed slightly and installed:
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Heater core coolant pipes swapped out for non corroded ones and ready to install:
056s8kvu.jpg
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And in
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Clutch line and other bits added:
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Dashboard is in:
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Sometime back we swapped in 540 audio wiring. Since connecting the battery, we found that some of the speakers weren't working. 
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The culprit...
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Swapped it out and now all speakers emit wonderful noise.
065ipkmx.jpg

 

Front centre console and glovebox are in.
066nzjcv.jpg

 

 

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Some more interior pieces added:
0785ij15.jpg

 

We found out why stuff wasn't working in the rear hatch.
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Sorted.
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Cut up a front passenger side wiper, trimmed the rear one...and viola.
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Repaired and painted the hatch tool holder thingy...whatever you call it.
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Sprayed some more stuff.
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Some sport seats.
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Never thought I'd see a brand new M5 rear bumper.
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And of course you have to "test fit".
076gskdu.jpg

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Swapped on another bonnet. Much better condition than the first.

080sykbe.jpg

 

Put a stiffner in the rear bumper.

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Rear crossmember installed.

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Front passenger door card in.

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Front drivers door card in.

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Windscreen wipers installed.

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1 x dirty engine.

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1 x not so dirty engine.

088joji0.jpg

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Replaced some seals:
092vojwm.jpg

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Right engine mount:
095epkmx.jpg

 

Left engine mount:
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Alternator power cable and knock sensors:
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Waterpump:
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Coolant accumulator:
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Dampner:
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Alternator:
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Tensioners and pulleys:
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Belts and power steering pump:
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Redone power steering line and more stuff:
104oukml.jpg

 

Tappet cover gaskets are next. Previous owner used copious amounts of gasket maker...yay.

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I like how clean the motor is looking, keep up the good work.

 

Not sure if it would work on different brands of instant gasket but over here you can get Hylo Clean which is supposed to break down Hylomar, the clear blue instant gasket. Could be worth a shot if it's caked in it?

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@Duncan - Thank you sir

 

@FLX - Thank you sir. Fortunately the gasket maker came off quite easily (I think it was recently done. They must have taken the covers off and just added the sealer to stop it from leaking - So silly). The old gaskets turned out to be more of a pain in the butt to remove.

 

Onto some updates:

 

Flywheel and clutch mounted
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Intake manifold installed
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Tappet cover redone
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Injector testing
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…and installed
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So close
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Fun times.
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Cleaned up the gearbox, replaced seals etc
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Now I have something to play with…
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Slave cylinder installed
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Darnit…
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Installed the tool holder. Looking for one in better knick.
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imageproxy.php?img=&key=a752e9eef3625401124hcjik.jpg

 

Edited by Uber Soldat

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so satisfying when the amount of work spanning months gets condensed in such a heavily detailed slideshow of pictures.

 

hats off for the work, keen to see more, we're almost there !!

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@t.wak - Thank you sir

 

@Mazz - Thank you sir...as well. 

 

 

Update time!

 

An oil pan - I think it's clean enough.
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ooooh...wiring
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And done
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They got it right the second time around...sorta
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Nice and shiny
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Time for a first start with the obligatory missing exhaust

 

Its finally on the ground. Have to do something about that wheel gap
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Unfortunately, we put the exhaust back on. Far too quiet now.

 

And it actually drove, quite nicely. Tyres are rubbish so couldn't really tell if there was any propshaft vibration.
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Bath time
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Added a plate surround and a badge
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Trying out a Dynaudio wheel well subwoofer. Really impressed with the bass output
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No body smuggling here...I swear. Added some throwing star covers. They need to be sprayed silver again.
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Now this is going to be interesting. More on this later.
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Great success.
139pdkxn.jpg

Edited by Uber Soldat

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Hat's off to you, top work there.

I wish I had the space to undertake this kind of stuff.

So frustrating when you have the tool's, knowledge and skill set but no workspace. 

 

Anyhow looking forward to more installments.

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Well today I learned throwing stars are actually a trim, they look great on the car. You must be chuffed to have it up and running, the hours are finally paying off!

 

Has there been much issue with working on it outside down there? I'm starting to notice the change in the weather here again, it's a little cooler, windier and rainier. I did notice the tarp but figured you probably don't get many showers?

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@Dirtydiesel - Thank you sir.

 

@FLX - I am extremely chuffed. At this stage its easy to forget it started as a shell. There hasn't been too many issues other than the tree nailing you in the head with those round balls of pain. The rainy season starts now though, so it will make things a little interesting.

 

Onto another update.

 

The Touring chronicles - Part...Complicated friggen sunroof 

 

First off, find all the broken pieces...

 

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Have a spare sunroof cassette and strip it down

 

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Cables and stuff

 

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"Repaired" actuator thingy

 

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These hold up and move the rear panel

 

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All assembled.

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Sunroof "bench testing"

 

 

Removing the current cassette

 

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And the reason it didn't want to work

 

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Swapped in the other cassette

 

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And added some panels. 

 

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Viola. When plugging the motors up, they didn't want to sync (They weren't connected to the cassette at this stage). When pushing the button up (Which would presumably sync the motors) the front motor would just spin for around 20 seconds and stop. Pressing the button in anything other direction, nothing would happen. The rear motor wouldn't do anything either, except a bunch of clicking relay noises from the module. Being a bit hesitant to connect the motors to the cassette itself for fear of breaking stuff, we read about the motors needing some resistance i.e grabbing onto a cable, in order to sync. We put some vice grips on the gear so it would jam against the motor housing to create said resistance when moving and the motors synced. We were then able to put the motors into their "rest" positions and bolt them onto the cassette.

 

 

More celebratory pictures. I can now retire the darn tarp. Thankfully it doesn't leak...so far.

 

153egjmf.jpg

154zlkn9.jpg

Edited by Uber Soldat

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@Mazz - Thank you sir. If it weren't for my father helping, it wouldn't be anywhere near where it is today.

 

@Duncan - BMW Touring - Harlequin edition :D 

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An overdue update...


Once the seats were plugged in, fuse 5 kept blowing. We stripped half the interior trying to find the fault, thinking it was something else. Took the seats out again and found the issue. Extra crispy wiring. Not sure how the previous owner managed to do that.

 

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The seats were stripped down and dyed black.

 

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And installed.

 

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Onto the headliner recover. Thought we'd try this ourselves.

 

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The master upholsterer himself. I just watched.

 

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Dyed the visors and some other bits.

 

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Some cargo nets. Thanks to Mr Sutton.

 

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And a cargo area cover. Again, thanks to Mr Sutton.

 

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Was about time to sort out the ugly wheel gap. Borrowed some springs on a non return basis. These come out of a M20 engine 525 sedan. They work surprisingly well in the touring.

 

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Added some Mtech skirts.

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Have never really been happy with the look of the dyed carpets. The outer sections didn't match the center main board. Used a can of Rustoleum Fabric and vinyl dye to correct them. Once they're sprayed, the fibers tend to clump together. Let it dry and then rub the carpet with a damp cloth to get the OEM feel back.

 

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The cargo area cover looked a bit tired. Redyed that as well.

 

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Found some old matts. and well...you guessed it, they were dyed to match.

 

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Yet another bath...

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Dyed the trim piece aorund the sunroof opening.

 

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Not bad methinks.

 

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Was not a huge fan of the black centres. Thought Gunmetal might look better.

 

187zpkzb.jpg

 

188q0kg0.jpg

 

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190uejdm.jpg

Edited by Uber Soldat

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