(1972) BMW 2002 Tii

  1. B1N9S

    B1N9S Member

    Messages:
    308
    Location:
    Conwy, UK
    Well, I may as well start a thread on my project. It has been ongoing for about 18 months, but only the last 12 have been in anger !!! Once I managed to get myself a decent place to work on it.

    I bought the car, knowing it needed a 'bit' of work and intended on it being a nice little project, but as with most 70's cars...the more you dig, the more rust you will find !!! I think I knew when I bought it, but went with my heart rather than my head and bought it without really giving it a good look over...idiot !!. But, it is an early model and was all original, matching numbers car, so if I didn't take it on, someone else would AND the guy had a second 1602 project, so I took them both !!!

    I should explain, that I am not a welder, or bodyshop guy, or even in the car trade. I work as a radio engineer, so I am on a steep learning curve and welcome ANY comments, better if they are constructive.

    So, here is the car when I bought it. Doesn't look too bad !! Eh !!

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    So initially the plan was a quick tidy up, get the bad areas welded up by a pro and off she goes. But once I started removing the interior and saw some old poor MOT patching, I knew I would need to dig deeper and decided to wait till, I had somewhere better to work on it. We were looking to move house anyway, but this kind of pushed us along and I now needed to find a house with a decent garage.

    So, we finally moved 6 months later and I inherited a nice double garage with an inspection pit !!! Bonus !!! I have since extended the rear of the garage with a 6x3M extension, so it is a really good size. So the tear down began properly about 12 months ago.

    Engine out:
    GEDC0361.JPG

    Subframes out:

    GEDC0377.JPG

    And then, onto the body inspection......
     
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  2. slim_boy_fat

    slim_boy_fat Forum Supporter

    Early round-cluster tail light model, well worth saving. :clapping:

    I like threads like this, keep the progress updates coming. [saw your other thread re panelling......:)
     
  3. B1N9S

    B1N9S Member

    Messages:
    308
    Location:
    Conwy, UK
    The bodywork was in pretty poor state, so, I just kept digging !!! Once the glass was out, even the frames were rotten :ashamed:

    Here is what I have found !!!!

    PassengerApillartop.JPG

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    RoofApillar.JPG

    So, like I said, I kept digging !!!! Passenger side.

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    Drivers side was pretty much the same. Inner and out sills and A posts all rotten.
     
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  4. B1N9S

    B1N9S Member

    Messages:
    308
    Location:
    Conwy, UK
    In all, I would be here all night showing pics of all the rot !!! :laughing:. So, Basically it goes like this:

    All new Inner and outer sills, both sides.
    New A posts both sides.
    New Boot floor
    New rear quarter panels (my choice really, as I couldn't be arsed trying to straighten the old ones) !!!
    Repairs to both front floors and a section of the rear drivers floor.
    New passenger door, possibly a drivers door, if I can stomach the cost !!!! The original isn't too bad, but needs work.
    2 x new wings
    New front panel (Found a good 2nd hand one)
    Replace the roof, since it was rotten following a Webasto install.
    Replace the parcel shelf
    Bulkhead repairs
    2 x rear inner wheel arches.
    New rear panel.
    Repairs to A frame, both sides.

    As you can tell, I do enjoy a challenge !!!!! :laughing:.

    Work done so far.

    Both Passenger and Driver side sills and A post repairs done.
    Passenger side floor repairs done.

    Cut out rear panel, boot and rear quarters and parcel shelf. All panels have been test fitted (numerous times), I am waiting on a spot welder to proceed with fitting. Pic is just a quick shot taken during one of the on/off, test fitting jobs !!!

    GEDC0953.JPG

    Here is the rear panel, test fitted : The indicators will need more work though !!!

    GEDC1063.JPG
     
  5. B1N9S

    B1N9S Member

    Messages:
    308
    Location:
    Conwy, UK
    Carried out major repairs to the front window frame, common area to rot and I had a donor shell, with good metal here, so I had no choice but to chop out the old and insert a new piece on the passenger side. The drivers side, was also rotten, but I have managed to repair that side. The most difficult bit of this job, was deconstructing the donor car to get what I needed. But both side, now look really good, they will need a skim of filler, but still pretty good.

    Anyway, remember this !!

    PassengerApillartop2.JPG

    Deconstructed the area.

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    After a few hours of grinding and a Dremel, I had this left, rot free !!! And all braced.

    GEDC0924.JPG

    Test fitted the 'new' part.

    GEDC0929.JPG

    There was a small area of rot on the 'new' section, that I cut out and fabbed a new piece. But there was a single weld, inside to the top of the A post, so this was actually not a bad thing !! Since I could get the torch through the gap.

    GEDC0937.JPG

    Plug welded to the A Post. Remember, I am not a welder, so don't gasp !!! You can also see my other repairs, to the inner wing area...mmm !!! All of this lot has since been tidied and it looks good !!!

    GEDC0946.JPG

    And all welded in at the top.

    GEDC0945.JPG
     
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  6. p0689109 Member

    Messages:
    1,603
    Location:
    stoke on trent,england
    Not bad for somebody who says he cant weld. Thin car body welding is a skill all by itself and you look to have a good mastery of it. Keep up the good work.
     
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  7. B1N9S

    B1N9S Member

    Messages:
    308
    Location:
    Conwy, UK
    Drivers side, looked just as nasty, but was actually repairable, using a donor.

    GEDC1117.JPG

    Amazing how good metal can look, until you give it a good rub !!

    GEDC1119.JPG

    GEDC1121.JPG

    This was INSIDE, after removing the initial rotten bit !! The top of the A post.

    GEDC1122.JPG


    So, I decided, these areas could be patched, since there was enough good metal around the rotted bits. So That's what I did.

    Donor part.

    GEDC1124.JPG

    After much chopping and shaping, I ended up with repair panel. The rusty bit in the pic, was just surface rust and cleaned off fine and the whole part got a healthy dose of Dinitrol rust treatment.

    GEDC1136.JPG

    Test fitted.

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    The other 'top' section was patched using a separate piece from the donor.

    GEDC1141.JPG

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    archie2000 likes this.
  8. B1N9S

    B1N9S Member

    Messages:
    308
    Location:
    Conwy, UK
    Continued.

    Almost finished. Needs some tidying up.

    GEDC1145.JPG

    And on this weld.... You can see why I joined this forum !!!!!

    GEDC1146.JPG
     
  9. B1N9S

    B1N9S Member

    Messages:
    308
    Location:
    Conwy, UK
    So. I am now at the stage of about start fitting the rear end...All of it.

    GEDC0951.JPG

    Then onto the drivers floor panel and chassis rail. More of that later !!

    And today, I decided to see how bad the bulkhead repairs are going to be and I need some advice on where to start. there are some complicated looking shapes, so not really sure. Anyone ? I removed the scuttle panel, to get better access to the area.

    There is basically, the bit below the pedal box, where the master cylinder has been leaking (common issue) and then the main area is where the scuttle panel was spot welded to the bulkhead, which has rotted out beneath.

    Any suggestions on how to tackle this mess ? I will try and get some better pics, but my camera is messing about at the moment.

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    slim_boy_fat likes this.
  10. B1N9S

    B1N9S Member

    Messages:
    308
    Location:
    Conwy, UK
    Thanks mate. You are right, it is taking practice to get this welding malarkey done !!!! But I have to admit, I am absolutely loving it !!!
     
  11. B1N9S

    B1N9S Member

    Messages:
    308
    Location:
    Conwy, UK
    Cheers Slim_boy. Definitely worth saving, emotionally though, rather than economically !!!! It is costing me a fortune !!
     
  12. DeanR32 Member

    Messages:
    106
    Sunny Essex
    A proper project there mate. The repairs so far look great though. Good work, and keep this updated.
     
  13. B1N9S

    B1N9S Member

    Messages:
    308
    Location:
    Conwy, UK
    Cheers Dean. I have only posted a few pics, as I would be here all night mate, there are tons. Here's a few more of the inner wheel well. Both sides got the same treatment.

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  14. striker Member

    Messages:
    344
    middlesbrough
    Very nice..great job. I had a 2002tii lux I think it was on a M plate. It was 33 years ago. Fantastic car, proper wolf in sheeps clothing!
    It had the square back lights. I put new wings and a front panel on it and did a full respray. I sold it to by a mk1 RS2000 escort.. wish I still had them both. I was only 18 and I remember the insurance was a fortune!
     
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  15. B1N9S

    B1N9S Member

    Messages:
    308
    Location:
    Conwy, UK
    Wow. I bet you wish you still had both !!! MK 1 RS2K's are fetching 35k and still going strong !!! The Tii's are starting to realise good money, but they'll never be as popular as a fast Ford here in the UK. I might break even, if I am extremely lucky !!! LOL. I do have a 5 speed box and a LSD to go in, so it should be a nice drive.
     
  16. B1N9S

    B1N9S Member

    Messages:
    308
    Location:
    Conwy, UK
    Been a bit slow on this lately. Still in the process of doing the bulkhead repairs. Today, I decided to tackle the repairs to the scuttle panel. The lower edge was damaged on removal and was rotten anyway. So, it had to be cut out and replaced. No donor available, so I had to scratch this piece from some 1mm sheet.

    I have since tidied the welds and added a bit of filler, but no pics of that yet, sorry. I am waiting for some epoxy primer to arrive, then I'll give it a coat and leave to one side until it's ready to fit.

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  17. adamss24 Member

    Messages:
    35
    Location:
    London
    Very good results- your welding still needs fine honning but kudos to you for undergoing such a major project with relatively zero experience !
     
  18. B1N9S

    B1N9S Member

    Messages:
    308
    Location:
    Conwy, UK
    Cheers Adam. I do enjoy a challenge and I love learning new skills.
     
  19. Wallace

    Wallace Member

    Messages:
    6,099
    Location:
    Staines, Middlesex, England.
    Coming on well, are panels easy to get hold of?
     
  20. lchris21

    lchris21 Member

    Messages:
    1,129
    Location:
    South Wales
    Love a good retro-resto...........some quality metal bashing there :clapping:
     
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