'88 BMW E24 635CSi Highline

[Jorge]

Yeah I am. Whilst the ACs are properly built

[Jorge]

[Alex@BagRiders]

So it begins!!

[P78]

So it began

finally


can't wait to c the result G.

[Jorge]

Rali, I'm gona email you soon. I need more bits! I can get it installed for now though.

Currently sat underneath working out how I can hold a bolt inside the car whilst I tighten the nut outside on my own lol

[Alex@BagRiders]

Rali, I'm gona email you soon. I need more bits! I can get it installed for now though.

Currently sat underneath working out how I can hold a bolt inside the car whilst I tighten the nut outside on my own lol

That seems like a challenge! Let me know what you need man

[Jorge]

IMG_4389-1 by Jorge-, on Flickr

Slowly, but surely, progress is under way.

Need to go buy more drill bits and cutting discs today as the top mounts aren't perfect.

[Nuts]

wow bud, nice clean 635 you got.
I love your current wheel, whats the size and offset?

[Jorge]

Thanks man. AC Schnitzers, offsets are above, something like 2 and -6, 17x9/10.

Some photo progress. Waiting for JamesB to sort out some more pictures.

Took the struts to a friend to weld them together, took a while to find someone who could help me out.

The workbench:



Firstly, prepared the cut eyelets for welding to struts.



These were then welded, 1/4 at a time, to the bottom of the rear struts.


Rear struts complete. Easy as that.


Next, after removing the shock from the front hub. The tubes were cut down. This probably should have been measured as Negative_Camber did with his, to act as a perch for the Airlift strut, but being impatient they were just chopped.


The supplied outer pipe sleeve was then ground down to a flush fit with the base of the hub.



And tacked in place, as always, safety first.


Welded as far round as possible, this is about 3/4 of the overall tube but should be more than strong enough to hold it.






And complete



Unfortunately, I didn't have a wheel in the car to test how low the strut can go. I went home and measured up with a rear style 32. It was close, this is with a 15mm spacer.



Took them back to my friend to weld the next morning, jobs a gooden. 1/4 at a time again and allowed to cool.


Tested with a front ACS Type 1, only a 5mm spacer was required to make it fit.

Other progress over the weekend included drilling and cutting down the top mounts. Unfortunately, I fucked up the holes and they're slightly out of position for the front turrets. Not a huge problem, but it is when you don't have any drill bits.

The same issue affected the rears, we could not drill into the turrets for the airlines. This meant that late on Saturday evening I had to call it quits. I missed taking it to the BMW Festival at Gaydon yesterday.

Been out today with a long shopping list to make sure I got everything possible as to not get in the way of fitting:
16x HSS Drill bits (1-13mm)
1x Counter sink drill bit
3x Cone drill bits
6x Hole saw bits
5x Cutting discs
2x Flap wheels
1x Hammerite Satin Black Spray
1x WD-40
1x Packet of rubber grommets

This is to add to the growing list of shit I have had to buy already, had to used loosely as buying tools is quite fun so why not when you need to...?
Angle grinder
2x cutting discs
Gas soldering iron
Impact wrench
Needle nose pliers
Length of 2x4 wood
...probably more?

Back to it tomorrow, hope to see it aired out. There are not many jobs left to complete (as a list for myself)
- Drill top mounts to fit
- Press in studs
- Fit top mounts to struts
- Cut off drop link mounts from old
- Weld on drop link mounts
- Fit front hubs/shocks
- Fit braided air hose from interior
- Cut already laid airline to footwell on N/S
- Cut airline on O/S, refit carpet, accelerator pedal, steering column trim, bottom dash panel
- Drill holes in rear turrets
- Fit rear struts
- Connect already laid airline to rears
- Program the controller

Not much really....

[Royal_T]

Just plan nuts..

[Jorge]

And the sorry state of it.

BMW E24 635CSI by Jorge-, on Flickr

BMW E24 635CSI by Jorge-, on Flickr

[NegativeCamber]

yes! this makes me happy. o how i wish my 7 was a shark nose like yours....

[Jorge]

Your help has been an absolute blessing in this build man. I half wish this was an E23 to be honest. Swap?

[NegativeCamber]

Your help has been an absolute blessing in this build man. I half wish this was an E23 to be honest. Swap?

no problem man. i anxiously wait to see this thing dumped. sure, we can swap nose panels.

[DannyE32]

this is so awesome that now im following you on instagram