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E36 Wide Arch Saloon

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  • E36 Wide Arch Saloon

    About time I started a build thread for my home grown M52 '95 328.

    Started off as your everyday beater covered in scratches and rust, what you'd expect of any 18yr old car I suppose. Here's a picture of it the day I picked it up alongside my daily at the time, another project e36, this one only had a pitiful M43 1.6 lump mind.

    First things 1st , have a chat with my nan and ask if I can use her double garage again to start the project, got the all clear and the 1st thing on the agenda was to start the strip process.

    After some of the panels were removed it was time to start putting my own little twist on things. Time for a browse on ebay to find myself something different, arches.

    After taking the plunge and purchasing the arches , that was it , no turning back , I was intent on building a wide arch 328 'loon.
    While I was waiting for the arches to arrive and had a few weekends free I decided to get the entire body flatted back using the trusted DA sander and marked out any imperfection's etc..

    Whilst doing this I remembered the drivers side wing had completely rusted through so a trip to the local breaker was in order, picked up a 2nd hand but solid wing for pennies.

    Arches turned up so was massively excited to get down to the garage and try and figure out what I will need to make them fit. That was the plan until I arrived and saw this.....
    The neighbours had decided to have their roof redone and told them that the garage was unused.
    %$%^$^$£%$

    I calmed myself down and then focussed on the job in hand , these arches, tried them at different heights with different curves until I found the shape I was happy with and then came the fun. Started the process by prepping the wing as if it was going to be painted, keyed the surface and then pop riveted the arch to the original wing, for that extra bit of security I then fibre-glassed over the bolts to ensure that they wont pop out sometime in the future.


    After the arches were stuck and solid it then became a very time consuming task of deciding how to blend the arches in to the nose cone and front bumper. After lots of filler work, This is what I decided on ..

    It looks very aggressive but with a wheel filling the arch is should look much better.

    After getting both arches and wings located and secured properly I decided to primer them in one solid layer so I could see how they look as one piece, I was well impressed..



    I forgot to take any photo's of cutting the inner arch out but it was lots of fun and I then fibre-glassed the inside of the arch to seal it so it doesn’t rust from the inside out.

    After getting both wings sorted I thought id put the M bumper on and see how it sits. So glad I decided to give this a go

  • #2
    With the front's done and pretty much ready for paint it was time to take on the rear arches, I knew this was going to be a massive challenge as the rear quarter panels aren't removable like the front wings so it was a case of careful planning and hoping that the first cut with the angle grinder would be the correct one. Here goes nothing

    Again, Got carried away with getting things done and forgot to take photo's of cutting the rear arches and attaching them etc. but it was done exactly the same way, measure, bolt, fibre-glass, fill.

    After all of that was complete it then became the time to figure out how to blend the arch back into the skirt/sill of the car without looking crap but also blending it in to the rear bumper.

    It looks completely ridiculous on the standard wheels but when those arches are filled with a dished negative offset 10j wheel I'm hoping it will all come together

    Now that the biggest part of custom fab is out of the way its time to focus on getting everything ready for paint. On my previous e36 I sprayed the car as one complete unit with the doors, boot etc. all bolted up but masked , with this one, I've decided to do things more thoroughly and remove every possible panel so a good even coating of primer, paint can be applied with ease of access.


    Now that 99% of the fabrication work is complete its time to start prepping the garage for a dust free(ish) environment. Bring on the home made spray booth My plan was to make the garage air tight so no dust could interfere with the spraying process and spoil all of the hard work at the penultimate stage. So, its time to BUILD a extraction/circulation fan system, some MDF, air filters and Correct fans were all that was needed to make this work and this is the outcome of a weekends graft.

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    • #3
      Fans and filtration system ready, now what's the point in having all the filtering equipment if your going to let the dust in under the door or through the roof? Time for some special spray specific tar paling type material to ensure that the booth remains airtight. To do this I stapled the sheeting to the joists in the roof and on the sides of the unit and then propped them up with off cuts of wood to support the structure, the finishing touch was then adding a very generous helping of gaffa tape along all the seams to ensure there was no access for the air in/out except through the designated filters.


      Managed to get a little bit of spraying done today 20/06/13 although the weather really wasn't on my side, managed to get the panels in primer properly using the Clarke pro spray gun and 2 Hunter compressor's to maintain the correct air flow. Here's a few snaps that I took after hand sanding the primer pack with 320 grit paper.


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      • #4
        Weather was decent today 21.06.13 so decided to have a go at getting some colour down on some of the panels, got a fair bit done so decided to take a couple of pics of the door as it was done 1st. The colour looks a deep red at the moment but thats due to the poor lighting of the garage, the colour is Valencia orange which is found on the 2012 BMW 1M. I love it! Anyhow, enjoy.



        Managed to get some more paint down on the panels today 28.06.13, instead of doing what everyone else does and picking nice colour, putting it in the gun and spraying it, I decided to add another little twist to the car, flake! Some of you will call it chavy/ricer etc. but I think it adds a lot more depth to the paint, and when the sun hits it,the paint sparkles well. I haven't gone ott with the flake and kept it subtle with a orange flake so it takes a double look to notice the flake, just another thing to make it that little more unique. Again, pics taken on iphone camera so doesn't pick up the pearl, flake or even the colour properly.



        Today was a huge day progress wise, ALL THE PANELS ARE FINISHED! Thats right , today, the 03.07.13 is the day that every removable panel has been painted,flaked and lacquered. Things are finally taking shape and starting to see how the car looks as a whole unit. As well as the shell, I’ve still got the front bumper,rear bumper, side skirts & trims to paint but the most of the painting is done. Cant wait to put the spray gun away and get out the DA to get some colour sanding and mopping done to bring out the epic shine this colour is hiding Anyway , heres some pics of the panels on and ready, loving the evil width this thing has





        Now that all the removable panels are painted and ready to go, its time to focus on the shell, first things 1st , get the panels off the car so I can start masking the shell. Thanks to my nan for letting me use her back garden(which conveniently backs on to the garage).

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        • #5
          Panels out of the way, lets start the massively time consuming task of masking the car up for primer.
          Unlike a lot of hobby sprayer's I want this to look as good as possible and also look like it was straight off the production line. I spent a fair while masking up the engine bay and all wires etc.. so I could get the suspension turrets and visible metal painted, I would have loved to be able to whip the engine out and completely blast the engine bay but due to my daily e36 on its last legs and no engine crane I decided to do the best that I could without wasting time and money.

          Now that the engine bay's done, time to tackle the rest of the car. I decided to get extra safe with my masking and put tape frame underneath the paper for that extra bit of rigidity and ease.



          I masked the roof on auto pilot, for some reason I hadn't processed that it also needs priming, wasn't too much of an issue, just meant I had to dig the razor blade back out and remove the paper tape along the lines of the roof.

          After all the masking was completed and checked to make sure there were no gaps or things incorrectly masked, was time to lay the primer on the shell, this was another benchmark moment for me as it would be the first time that I would see all the arch work/bodywork in one solid colour to see how it blends.



          I was impressed with the overall transition from original bodywork to aftermarket custom bodywork, things are really coming together now. Colour Next.

          Well, after 3 coats of primer and then sanded with 320grit paper and a DA, it's time for colour, this is when it really starts looking like its in its closing stages to me, again I have focussed on taking a picture of the arch work to see how it blends and works with the original bodywork.



          I'm well impressed with how the paint has gone down and the finish looks good (considering this is the base coat before clear coat and flake etc.)

          Got the clear coat and flake on the shell, roof sprayed and cleared in black today, really impressed with how it has come out. Again , iphone pics so sorry for the bad quality but if you look carefully, you can see the flake popping on the rear arch.


          After seeing the shell in all its glory I couldn't resist trial fitting the bonnet and front wings, this is the most complete I’ve seen it in a long time.

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          • #6
            Wow..
            In a world of so much no..this is so much YES!
            Subscribed!
            Lovin the cherry


            My Build thread..http://www.stanceworks.com/forums/sh...ad.php?t=46154

            Comment


            • #7
              After seeing the body coming together I was eager to get the other body panels on and secured so it can start resembling a car again. Before I could put the doors on I thought that it would be a lot easier to swap the leather interior over from my current daily e36. The cloth seats are going into my daily and I will be sitting on poverty spec seats until this one Is on the road, shouldn't be too long now.

              With the leather out of the daily, a quick wipe over, hoover and some awkward manouvering, managed to get the leather in the 328 and I think it looks brilliant against the orange shell.

              After the interior was in, secured and looking fresh, I could finally get the doors on. In the time that I was doing this I also wired up the window washer jets, electric windows and secured the bonnet properly. My M3 rub-strips also turned up this week so I have trial fitted those to the doors and thinks its a nice contrast against the shell. The strips have to be easily removable as the entire shell will be colour sanded, mopped/polished and possibly re coated in clear coat to get that show car shine.

              Now that the doors are on and windows wired up, I can put the windows up and give the car a good clean. A couple of snaps I took post wash.



              Car washed, time to get the plastics and trims all prepped so all the spraying is out of the way, this pic is all the trim except the rub-strips from the bumpers. The process of getting these prepped was a very mild sanding then scotch brighting the panels to give them the ultimate key for the primer and paint to stick. Before applying primer I used Plastidip which also helps in getting a good even finish on plastics while using general primer.

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              • #8
                What a build! Cannot wait to see this thing all finished up, looks good so far.

                𝔣𝔬𝔩𝔩𝔬𝔴 𝔪𝔢
                @𝔳𝔦𝔳𝔢_𝔪𝔢𝔪𝔬𝔯_𝔩𝔢𝔱𝔦

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                • #9
                  This is the shit, what style of wheels are you thinking of?

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                  • #10
                    Are you a painter by trade or just a spray your own car kind of guy?! Turned out pretty awesome! Nice work. Coming together nicely.
                    [COLOR=#ff0000]Lifetime Project[/COLOR]--- 1999 Mercedes C230 Kompressor, but converted to Turbo. Attempting to finish it up.
                    [COLOR=#ff0000]The Daily[/COLOR]---2011 C350 4matic[COLOR=#ff0000][/COLOR][COLOR=#ff0000][/COLOR][COLOR=#ff0000][/COLOR]​

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                    • #11
                      Hey guys, thanks for the comments, in regards to wheels i have a few sets in mind, hoping to give it a nice bit of bling but still keeping it looking like a race car. im not a sprayer by trade no, I actually work as a door supervisor (bouncer).

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                      • #12
                        coming out very nice!subd
                        Instagram: Dariusrusu
                        Vwvortex: Vwdubluvin

                        c by [url=http://www.flickr.com/people/55829963@N05/]

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                        • #13
                          This should be cool..
                          Instagram: @B_OLSEN_
                          1988 FC3s-LS3 track slut~in progress~
                          1991 S13 Coupe-LS1 street beater
                          2004 G35 Coupe track model-Work Wheels Static daily
                          TUMBLR

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                          • #14
                            Mini update: had an hour spare today so popped down the unit, didnt want to waste time setting the conpressors up etc so decided to colour sand the rear quarter by hand. No pics but i can assure you guys that its worked brilliantly with a good polish this car is going to have such a deep shine. Cant wait!

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                            • #15
                              This is just unbelievable! Where in the UK are you based?

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