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

[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

[znxe]

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

[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

[herrakani]

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

[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?

[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

[MParallel]

Epic work!

[herrakani]

Hats off, brother. I love your build.

[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

[cossie]

The wheels turned out great! :




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


-Timo

[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 car is back on wheels, first time since last august!!




Had to put the front wheels on backwards, otherwise the wheels would have hit the front struts..

The E34 rear ABS-sensor fitted after modifying the brackets:


Rear axle missing only sway bar and drive shafts:




Upgraded diff mount, all "empty" spots have been filled with rubber:






ABS-unit and front brake pipes on their place:




Fuel system ready at the rear:


A friend and i started to transfer parts from cars original doors to the new doors today. We got three of them pretty much sorted, only few parts were left un-installed.
These little tasks take incredible amount of time..

-Timo

[cossie]

Shiny new race car parts!





The other wide band A/F-meter is for my other project car.

-Timo

[Shepherd]

Awesome work!
Can't wait to see this one finished.

[cossie]

Thanks y'all!!

Yesterday i dropped the front x-member from the car so i could mount it under engine and check the aligment of the compressor housing on the rear turbo.
Started to fabricate wastegate actuator mounts. Original idea to use TD04s BOV block off plates as base didnt work, so i have to weld mounting points for actuator brackets to the compressor housings.

Figured out routes for oil return lines. They'll be more or less horizontal, but i'll try to get atleast a little slope on them.

The rear ABS-sensor mounting brackets need a little modifications to take E34-sensors, so i took them out from the trailing arms. Brackets need to be shortened and the surface where the sensor mounts is a bit different.

Bought a Optima YellowTop battery last week and ordered a tray for it from ebay:


I'll try to get the wheels assembled this weekend, also on the todo-list there are; wastegate actuator mounts/brackets, ABS-sensor bracket modification, sand blast and paint exhaust manifolts and turbine housings..

-Timo