E28 M535i from Finland - The project that got out of hand!

[cossie]

A long time since last update.

Have been sick for the past week, got well only yesterday. And I'll be leaving for last skiing holiday tomorrow. So no work will be done before next weekend..

Now, if I can have your attention.. I think you'll like these next pics..

































































Little teaser of the wheels (or one of them):


The original Arden centre cap:


MAE-style centre cap, i like these ones!:


P.S. These look so much better IRL!!

-Timo

[cossie]

The wheels turned out great! :




Also went on a skiing trip last week (third and last one this year) :


-Timo

[cossie]

Today it was time to add turbo return line fittings to the block.

First one took too long. First i tried to make R1/2" thread to the block for the fitting, but it didnt pan out. The fitting isnt in 90degree angle.
Then i tried to file and hone the hole so i could hammer the fitting to its place. That one didnt work out either as i filed the hole too big..

At this point i thought "F*CK IT!" and took the welder out and welded the fitting to the block.

Got the other fitting installed considerably faster




Also painted few spots of the carpet with rattle can. Some previous owner had red tray mats on the car and the paint had creeped through..
The tone seems to be off in the pics, but you cant see it with naked eye.
I think ill get one more can in one tone darker shade..


-Timo

[herrakani]

Hats off, brother. I love your build.

[MParallel]

Epic work!

[cossie]

Hats off, brother. I love your build.

Epic work!

Thanks!

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Things didnt go as planned today!

Took off the timing chain and lifted the head.
Found out that there has been extra stuff tumbling around in cylinders 5 and 6.

Pistons have pits, right at the edge of the piston on number six:






Pits on the head, really bad ones on number 6 combustion chamber:








I dont know if the head can be repaired and used. I think that ill have to get a set of used pistons and connection rods that are intact and use them with new rings. Also have to get new bearings for the bottom end.

At the end of the day i sorted out few bad wiring jobs done by previous owners.

-Timo

[herrakani]

Previous owner had a blown piston/valve and a set of used pistons maybe? I'd try to bottlebrush-hone the cylinders, measure and use them if usable. If not, just pucker up and get a set of new pistons and bore the cylinders. The head should work just flycut it by a hair or two. Is the nr 6 valve seats ok?

[herrakani]

Is the valves bigger in that one than in a regular m30b30 btw? I have a spare m30 in Helsinki.

[cossie]

Previous owner had a blown piston/valve and a set of used pistons maybe? I'd try to bottlebrush-hone the cylinders, measure and use them if usable. If not, just pucker up and get a set of new pistons and bore the cylinders. The head should work just flycut it by a hair or two. Is the nr 6 valve seats ok?

Is the valves bigger in that one than in a regular m30b30 btw? I have a spare m30 in Helsinki.

I think that its just regular M30B34 head, the newer style.
The damage has happened some time ago and been somewhat repaired. Valve seat job has been done. I just worried about the sharp edges on the head. They might increase risk of knocking in turbo use..

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Thought what to do about the damage on the head and pistons on monday. Then it hit me: "F*CK IT!, its time for a another donor car!" This time E34 535.

Went to check out one on tuesday and paid a reservation fee on it straight away.
Drove the car to my garage today..

Few pics:


















I'll take the engine, wheels and the phone. Other parts are going to be sold.
The phone is a old Bosch car GSM, fully working. Im going to install it into the M535..
Wheels are widened 17" steelies.

-Timo

[znxe]

wow,just wow u finnish people are crazy :d greetings from estonia,btw how much u want for the steelies?

[cossie]

wow,just wow u finnish people are crazy :d greetings from estonia,btw how much u want for the steelies?

Thanks!

Ill keep the wheels for the M535.

-Timo

[cossie]

Started to tear down the E34, less than 24hours after purchase :







Sorry about the poor quality of photos..

-Timo

[cossie]

Started tearing down the "new" engine. Seems to be in good condition. Well the cam has worn down on 1st cylinder. Fortenately the other head has cam near perfect condition.




Two M30s just hanging out:


Looks like factory added few stiffening ribs to the skirt of the newer block..

-Timo

[cossie]

Few updates in one post:

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Had to add the oil return line fittings to the new block:


Cleaned shadow line trims from flake paint painted by some previous owner of the donor E28.

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The newer block is different in few places compared to the older one.

I want to use the older style oil pan on the newer block (the sump is a little further back on the old one). The older pan has separate bracket for the lower gear box bolts, which is integraded on the newer pan. There isnt bolt holes for this bracket on the newer block.
First i had to drill two holes and tap them. Then i had to fabricate two mounts for the bracket.

Few pics of the mounts and the mods:

First the holes and M8 threads for the bracket:


Then fabricating the mounts..

Exhaust side:










..and inlet side:








Block with the new mounting points:


Ordered some parts: Athena head gasket, LUK clutch disk (unsprung), PPF Stage 1 Valve Spring kit.

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I dropped off the head to local specialist (http://www.kansiset.net/).

Got few pics from the guy whos fixing the seats and some other upholstery parts (http://www.stailaaja.com/)..

Seat sides have cracked:


New patches for them:


Some of the pipings are in poor condition, he had to replace few pieces of the leather:




Shifter boot had a hole in it, so he made a new one:




Then it was time to paint the parts and seats:




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Little teaser of the fixed front seats:


Parts painted with flat black, Black Satin and Wrinkle coat:




Bolted the turbos back together after painting the housings:


Sorry for the poor quality photos..

Brought the head home; valve and seat job done, deck level skimmed, new valve stems, assembled with PPF valve springs, CroMo retainers and Ireland Engineering HD rockers.

Ordered new piston rings and bearings for the engine. Also made a little over 300€ order to Pielmeir.

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Productive day at work! A adapter for mounting custom drive shaft to the gear box:


Got the deck level skimmed by Kansiset:


After that it was time to mask off the block and paint it with VHT Engine Enamel, flat black:




Waiting for the bearings and gaskets for the engine to arrive.

-Timo

[epearce]

Top build!