It begins: Another E34 535iT project! (56k warning)

[Mr Project]

Hi, I'm Mr. Project, you might remember me from such internet forums as this one, a couple years ago! I used to have a '91 535i, but I sold it a year or so ago to a local friend.

It used to look like this:
http://img226.imageshack.us/img226/2277/img0788large4yh.jpg

A few months later, he decided he really needed a minivan (boo) so he sold it to another friend of mine. About a month ago, on a quiet Saturday morning, I got a phone call from that second friend....he had just been rear-ended by a drunk driver.

http://img20.imageshack.us/img20/421/img2036large8on.jpg

I instantly knew this was the opportunity I have been waiting for and trying to arrange for years....I also happened to know of a 525iT locally with a blown tranny, owned by a mechanic friend of mine. Well, yesterday I managed to talk him out of the car for a reasonable sum. It's been sitting for 5 years in the back of his lot, so it is FILTHY. The paint is also in pretty sad shape. This is after a solid 30 minutes with my 2500 psi power washer:

http://img49.imageshack.us/img49/7258/img2031large3fc.jpg
http://img151.imageshack.us/img151/3817/img2030large2zi.jpg

As you can see, it's far from perfect, but it's all there. The broken headlights/grill won't be a problem, as the front end of the 535i is perfect and even has my old euro ellipsoids that I'll be swapping over.

I've wanted to do a project like this for a long time...I always loved my 535i, but I haul a lot of crap around pretty frequently, and who doesn't love the classic lines of the E34 Touring? I've always thought the big, torquey M30, combined with the 5-speed manual tranny, made for the best combination of performance and low operating cost of any E34 drivetrain, and combining that with the Touring body is my personal 'realistic' E34 dream car.

So, this is the plan for the final output:
1992 BMW 535iT
M30B35 engine
5-speed manual tranny
3.46 LSD rear axle
Sachs kit (this is still up in the air)
M5T sways (19/25mm)
Euro ellipsoids
EAT Chip

[Mr Project]

6/22/06 Progress

Yesterday I got the Touring towed to the house, so I have both cars at my 'shop', I did a little cleaning on the Touring, and got the front end disassembled:

From this:

http://img67.imageshack.us/img67/5571/img2040editlarge4sf.jpg

To this:

http://img20.imageshack.us/img20/6195/img2041large2pu.jpg

It'll be a little while before my next update since I have some 'around the house' projects I need to do this weekend. But I promise regular updates and as many pics as imageshack will let me host. :)

[kyleN20]

cool project, i envy peoplee who are able to undertake such things. good luck

[uflnuceng]

Way to think outside the box... interesting project :D

[Scott H]

rewiring to perform.


I've wanted to do a project like this for a long time...I always loved my 535i, but I haul a lot of crap around pretty frequently, and who doesn't love the classic lines of the E34 Touring? I've always thought the big, torquey M30, combined with the 5-speed manual tranny, made for the best combination of performance and low operating cost of any E34 drivetrain, and combining that with the Touring body is my personal 'realistic' E34 dream car.

So, this is the plan for the final output:
1992 BMW 535iT
M30B35 engine
5-speed manual tranny
3.46 LSD rear axle
Sachs kit (this is still up in the air)
M5T sways (19/25mm)
Euro ellipsoids
EAT Chip

[Ross]

Great idea. How about a giant hairdryer on that motor?

[kyleN20]

ditto

[Mr Project]

Yeah, a hairdryer is something I'd like to do eventually, but first I have to get this done, and I'm in the middle of a big Corvair restoration project as well. $$ is something I'm a lot shorter on than tools and expertise. :)

[DrewZ]

Enough about the stupid station wagon, let's see the 'Vair.


Yeah, a hairdryer is something I'd like to do eventually, but first I have to get this done, and I'm in the middle of a big Corvair restoration project as well. $$ is something I'm a lot shorter on than tools and expertise. :)

[Ross]

How about just selling the pair to me and getting on with the Corvair?
Tell us about the Corvair.

[Mr Project]

Hey, everything's for sale at the right price. :)

The 'Vair is closer to done than it looks, really, I swear. :) This is at the bodyshop where they have finished fixing my amateur work and are ready to spray the high-build primer, block and paint. I welded in quite a bit of metal on this car, and did quite a bit of work to get it straight. It's a '66 sedan, it was my second car, purchased when I was 17.

I have a few modern touches in the works for it...LED taillights, keyless entry, trunk-mounted battery, and yes, BMW wheels. :D


I've got a little photo album of the 'Vair here on this slick new site called Motortopia:

http://www.motortopia.com/garage/cars/Mr_Project

[uflnuceng]

Finally... someone who has more project cars than me!

[Ross]

I've got a touring of my own that I'm currently getting caught up with maint/repair, ALL the usual stuff. As it's nearly finished your project interests me. Define "right price" for me if you are serious.

[Mr Project]

Today's progress... I only had a couple hours to spend on the Touring after installing a window in the living room...which was just about 1/8" too big for the hole! That took a little more work than anticipated.

http://img45.imageshack.us/img45/9313/img2062large1dz.jpg

[Mr Project]

Well, here are a few pictures to tell a few thousand words. Progress is moving along pretty nicely, I believe I have less than 10 hours of work into it so far and it's actually mechanically pretty much stripped as far as I can take it for the moment. I will be rebuilding pretty much all the suspension, and pulling most of the interior out for the pedal and heater core install, but for the moment I need it to stay mobile, so I'll probably work on stripping down the sedan next:

M50 halfway out:
http://img164.imageshack.us/img164/5934/img2090large4yw.jpg

M50 in it's new temporary home (This is a truck that gets used as a truck!):
http://img392.imageshack.us/img392/9464/img2095large3ui.jpg

I'm EXHAUSTED! Heh.....ok, not funny:
http://img397.imageshack.us/img397/976/img21012vg.jpg

Ready for a real engine (sorry 525 guys):
http://img480.imageshack.us/img480/9081/img2102large0ut.jpg

[Dark Helmet]

1) glad to see you're getting the "hairdryer" talk over here too...

2) hmmmm, why does that corvair look so familiar.... hmmmmmmmm... oh yeah, now I remember.

3) You guys need to crack the whip on Armen on a daily basis... I like seeing visible progress every night when I drive past on my way home! :D

[Dark Helmet]

I want to know what was leaking on the crossmember... I can't even think of what part of an M50 would be right there and be leaking...

[Mr Project]

Soo tired. :)

Last night I got the donor car partially stripped. Hoping to have the engine out of it by this Saturday.

http://img233.imageshack.us/img233/8438/img2106large5ea.jpg
http://img238.imageshack.us/img238/2373/img2112large0pp.jpg

[Dark Helmet]

painting the valve-cover was the best thing you ever did to that car....

[Scott H]

to get the engine with tranny out. That's a lot to have to put back together.

[Mr Project]

I know it didn't have to come off, but I have to re-do the A/C, headlights, and grillwork in the Touring anyway, and frankly it only takes me a couple of hours to take it all apart. That time vs. all the delicate hoist work with the 'normal' method was a trade-off I was willing to make...it took 5 minutes to get the engine out this way, and I never even had to bend over into the engine compartment. :)

Sometime I'd like to try dropping it out from below...if I had a lift it seems like that would go VERY quickly.

[Mr Project]

6/28/06 update:

Doesn't look like much progress tonight, but actually the M30B35 is nearly ready to remove. I just have the shifter and guibo left to disconnect, then unbolt the mounts and away I go.

Not in focus anyway, so this is a little smaller:
http://img249.imageshack.us/img249/7936/img2114medium4cy.jpg

This was the really big news of the night....I never thought in a million years that my little $100 impact wrench would take off the main crank nut. I've been working out all the different options in my head....Build a brace for the rear of the crank while on the engine stand, devise some sort of holding mechanism from the front, borrow a 1" impact from somebody...But I figured, what the hey, before I pack it in for the night I'll give it a shot with my little gun with the air pressure cranked up to 130 or so.

http://img527.imageshack.us/img527/3194/img2116small6ki.jpg

And WHADDYA KNOW! It came off! I'm so shocked, and so excited all at the same time. It's nice when one thing goes your way. :)

http://img527.imageshack.us/img527/1721/img2118small9eo.jpg

[Mr Project]

So, of course, I immediately had to face the only real hurdle so far. The brackets that are welded to the body are different on the '92 then they are for the '91. It appears that the bracket for the PS reservoir, cruise control, and charcoal canister is totally different on the '92. Take a look:

'91 535i:
http://img523.imageshack.us/img523/299/img2120large24xv.jpg

'92 525iT:
http://img527.imageshack.us/img527/5716/img2121large9zs.jpg

Sorry for taking pics in the dark. When I get closer to reassembly, I'll try monkeying around with different options for mounting the 535i hardware. The only catch is that the PS hoses for the 535i are none too long and they have to stay with the engine that I'm swapping, so I have to find a way to adapt it. I'm really trying to avoid any cutting and welding on this project, but if I have to it won't be the first bracket I've fabricated. :) Any thoughts are appreciated.

[Ross]

How difficult is it to swap the inner fender?

[Scott H]

You asked me to explain a few caveats, and I gave you my phone number....you should have called. I believe you're making this part harder than it needs to be.


So, of course, I immediately had to face the only real hurdle so far. The brackets that are welded to the body are different on the '92 then they are for the '91. It appears that the bracket for the PS reservoir, cruise control, and charcoal canister is totally different on the '92.

Sorry for taking pics in the dark. When I get closer to reassembly, I'll try monkeying around with different options for mounting the 535i hardware. The only catch is that the PS hoses for the 535i are none too long and they have to stay with the engine that I'm swapping, so I have to find a way to adapt it. I'm really trying to avoid any cutting and welding on this project, but if I have to it won't be the first bracket I've fabricated. :) Any thoughts are appreciated.

[Mr Project]

Well, here is the latest update:

I decided to go ahead and set up the Touring engine compartment with all of the M30 brackets and repaint it. I only want to do this once, and I'm trying to minimize the number of things that are held on with zip ties. :)

Cleaned up Touring engine compartment:
http://img240.imageshack.us/img240/2706/img2132large4pw.jpg

Prepped Touring for air cleaner and ignition coil brackets:
http://img254.imageshack.us/img254/8505/img2215medium9kl.jpg

Brackets welded on:
http://img98.imageshack.us/img98/879/img2220medium6cu.jpg

[Mr Project]

Here's the PS bracket. You can see that rather than transferring the whole M30 bracket, I decided to cut off just the relevant portion and weld it to the existing M50 bracket:

http://img275.imageshack.us/img275/1411/img2221medium3oa.jpg

Here's the engine compartment after painting:
http://img84.imageshack.us/img84/5479/img2241medium8gq.jpg
http://img154.imageshack.us/img154/5365/img2240medium3sy.jpg

[Mr Project]

While the M30 was out, I decided to do a new timing chain with new gaskets and a new oil pan gasket. Here's the M30B35 with the new parts, and cleaned up a little for installation:

http://img212.imageshack.us/img212/9455/img2246medium9fh.jpg
http://img60.imageshack.us/img60/7979/img2248medium2ef.jpg
http://img212.imageshack.us/img212/7489/img2247medium5uj.jpg

[mholbrook]

Just a thought, you might want to replace the pan gasket while it is out of the car. M30's have a tendancy to leak at the pan gasket and the crank position sensor bracket. This is a lot easier to handle now since it is out of the car.

[t_marat]

Did you paint the car yourself in your garage?

[Mr Project]

Just a thought, you might want to replace the pan gasket while it is out of the car. M30's have a tendancy to leak at the pan gasket and the crank position sensor bracket. This is a lot easier to handle now since it is out of the car.

I agree. That's why I already did that. :) Of course, it looks like I might be taking the oil pan back off to use Winfred's wood-block-on-the-crank method of tightening the crank pulley nut.

As to the paint, yes, I did it myself. On the location, I plead the 5th. :)

[Jon K]

Paint looks good - where'd you get it? I will be respraying my engine bay when my motor is out.

As for what leaked ont he cross member of the M50 car, it was probably the power steering fluid it puddle on that frame rail and saturates EVERYTHING. Where is that M50 motor going??? I am PMing you.

[Mr Project]

M50 is gone, the guy I bought the Touring from wanted to keep it. Though he might sell it if you want, I can get you his number. It was a non-vanos, obviously.

The paint is Omni MTK single-stage, mixed to the BMW 273 Iceland/Island Green. I didn't bother with clear coat since it's in the engine compartment, but I put about 4 coats on.

[Jon K]

I have another M50 non vanos already I was just curious.


Where did you source the paint and how much?

[Mr Project]

Local auto body supply place called "Auto Body Supply". Seriously. It was around $30 for a mixed quart and some hardener, but I already had a gallon of reducer (about $20). It's cheap paint and a 'quick and dirty' paint job, but it looks a LOT better than before and should hold up for quite a while.

[Mr Project]

Not much by way of progress this week, and even less will happen this coming week. Heater core is replaced in the Touring, the evaporator is out for the R134a conversion, and I've sold a couple parts off the parts car.

Here's what I think is probably the toughest part of the 5-speed swap so far (not that I've done much so far!): The bracket for the clutch return spring.

This is the AUTOMATIC bracket: (I have the clutch master cylinder hanging in this picture)
http://img366.imageshack.us/img366/3476/img2287mediumao1.jpg

This is the MANUAL bracket:
http://img230.imageshack.us/img230/809/img2288mediumlb8.jpg

Notice that the little side bracket for the clutch spring is not on the automatic bracket. This bracket would be very difficult to swap...it goes up and over the steering column...the entire column would have to be dropped, and one of the bolts is even the 'non-removable' type with no head. You'd have to be able to get in there and cut a groove in the head, which would not be an easy task.

I've been debating the best way to go about this...if I could get the old one cut off in place, welding it on would be no big deal. I don't have anything remotely like the right tools to get that cut off in it's current position, though. I'm not even sure what they would be.

So, I'm working on getting the bracket out of the parts car, cutting off the clutch spring support, and then finding a way to attach it to the Touring.

I thought about fabricating my own clutch spring support from bulk steel, but so far that's not looking real great. I might still end up going that route, though.

'nmia's famous write-up here:
http://www.nmia.com/~dgnrg/page_41.htm

has this to say about semi-fabbing up the mount:
"After looking at it a little closer, I realized all I need to do was cut the the spring perch off the manual frame and weld it onto the automatic frame. I was apprehensive about welding inside the car, so instead, I made a small incision in the perch while still attached to the overall frame, and welded in an L-bracket which I cut out from 3/16" thick bar stock. I welded in another stiffener rib, matched drilled the two holes for the upper stud and fluid reservoir line, and then cut that small sub piece off of the manual bracket. I drilled another hole for mounting it in the car and that's all there is to it, no swapping of pedal brackets required at all and the only mod to the car was the drilling of a hole for a sheet metal screw thru the existing bracket and firewall."

I'm just really not sure how he would have cut it off without having the full bracket already off of the car. I have to assume he already had the manual bracket off, at which point this would make much more sense.

[Kalevera]

This is the one point with this swap on which I disagree with Don -- it's easier to pull the column and replace the pedal box than it is to modify the existing bracket in the car.

Removing the sheer bolt that partially secures the column bracket to the pedal bracket makes this job more difficult than it needs to be. While it is possible to remove that bolt in the car, it won't help in removing the column assembly, as the bolt doesn't secure the assembly to the chassis.

Deviation: if you DO want to remove that bolt (either for the tilt/telescoping retrofit or otherwise), the best way to do it in the car is with an air hammer with a chisel tip. Try a sharp chisel and a ball peen hammer, otherwise -- the technique is to cut then gradually turn (as I learned from an Aus truck driver...it will take out ANYTHING with enough diligence). The three sheer bolts in the column assembly have designed initial resistance. Once they're loose, they'll turn freely.

Like I said, you want to remove the entire column. Looks like you've got most of it apart already, but let's assure that the basics are covered. Set the steering straight, undo the throttle linkage at the pedal, undo the brake pedal to booster plunger by removing the clip and popping the rod out of the pedal. Disconnect all column harness connectors, hopefully the battery's disconnected so the airbag doesn't blow up. Remove one bolt and...I think it's...5...nuts from the lower pedal bracket. At least one of those nuts is hard to reach/hidden -- been a few months since I've done one of these, and these specifics aren't clear in my mind anymore -- and requires a decent swivel socket or tiny wrench to get on it.

If the car has shift interlock, disconnect the cable from the shift console and pull it back to the column -- don't disconnect it, it needs to be tied back else the key can't be removed from the ignition. Edit: something else that's not clear in my mind at the moment but may be applicable -- there's a long M10 (?) bolt that secures the lower bracket to the upper column and I don't recall whether it also attaches to the chassis, but it definitely must be removed once the column is out of the car to swap the lower bracket into place. Remove the two bolts that secure the upper column bracket to the chassis, directly below the instrument cluster. At this point, the column should literally fall out of the car.

Put the column on a bench, tie back the interlock cable, swap the pedal box and reinstall. Or, if you have a column without the shift interlock from the donor car, swap the ignition cylinders and be done with it. Here are a few pics:

http://img.photobucket.com/albums/v736/suzpectx/column-tiedshiftinterlockcable.jpg

http://img.photobucket.com/albums/v736/suzpectx/dash-cleanedupwiring.jpg

Note the visible bolt holes directly under the dash, this is the best picture I have ATM of this area, but it should give an idea.

http://img.photobucket.com/albums/v736/suzpectx/column-securityscrew.jpg



Another deviation: early E32/E34 manual/auto cars use the same pedal bracket regardless of what transmission was delivered with the car, so they all have the spring perch, even the 750s. Simply bolt on the clutch/brake pedals and clutch switch bracket.

I have an extra manual pedal box sitting around, if anyone is looking for one.


best, whit

[Mr Project]

Lowell, endless thanks for a helpful and informative post! Thanks for taking the time.

You're absolutely right, removing the column was not a big deal. I just had to dive in and start wrenching, and it became quite obvious how everything would come apart.

For the benefit of everyone else, steering column removal is pretty straightforward.

Assuming you've removed everything in your way up to this point...lower dash, column plastic, pedals, etc. You can probably do this with the pedals installed, but I'm not sure what all complications that might add. You'll also need to remove the accellerator pedal linkage.

1 - Just remove 2 bolts "A" from the front end of the column.

2 - Pull down on the steering wheel hub. This will give you enough clearance to reach the 2 bolts "B" with a box-end wrench or maybe even a ratchet with a short socket.

3 - Disconnect all the wiring harness connectors and pull the assembly straight off. The big nut on the column should pull straight off the steering shaft that goes into the box.

4 - Bolt "C" is my replacement for the headless shear bolt in Lowell's pictures. I tried welding a nut to it for removal, but it worked a lot better to cut a groove in the head and then use a hammer and a flat-blade screwdriver to spin it off. I used a low-grade metric M8X1.25 bolt to replace it.

http://img353.imageshack.us/img353/4919/img2350largegu4.jpg

[aston_jag_tech]

Mr. Project.

I like you detailed project. I also like the pics. Yea that crossmember soaked in P/S is very annoying. My P/S is pissing all over. Your fab work on the brackets look very clean, good job and good luck with everything.

-Scott

[Mr Project]

Well, I've actually been working pretty hard on the project lately, but it's not very exciting progress. :)

You've all read about suspension swaps before, and it's mostly that.

First I cut down the stock 535i bump stops...thanks to the thread here.
http://img171.imageshack.us/img171/8404/img2367smallnh2.jpg

Then I assembled and installed the rear strut assemblies (Koni/Eibach) and the fronts:
http://img213.imageshack.us/img213/3784/img2389smallen7.jpg
http://img178.imageshack.us/img178/1152/img2388smallzd5.jpg

I also removed all the SLS components...just the hardlines running the length of the car and the rear ride height sensor remaining.
http://img178.imageshack.us/img178/420/img2379smallsv0.jpg

Finally, I also swapped over the entire front subframe from my sedan parts car. It's got some relatively new steering parts, newish thrust arms, and better control arms, so rather than replacing everything again on the Touring, I swapped over the OK stuff from the sedan. If I can get a year or two out of this stuff before having to rebuild the front suspension again, I'll be happy.

[Mr Project]

Bunch of other little stuff done too, like the brakes are all bled with new pads and rear rotors, and started cleaning the impossibly filthy rear carpeted panels. There's a lot of hours of cleaning to do on this car.

As of tonight, I also learned something else interesting.

For some reason I was thinking that the stock diff in the Touring was a lower gear ratio than 3.46:1. However, cleaning up the diff a little revealed 4 interesting characters: S, 4, 1 and 0, in that order. It's a limited-slip 4:10 rear.

Is anybody else curious what an M30B35 wagon would feel like with a 5-speed and a 4:10 rear? I know I am. :D :D :D :D

If I can't stand it, which I think I won't be able to for very long, I'll swap the 3:46 in and go back to the stock combination. I've found that I can swap the diff in a shockingly small amount of time.

[Michael999]

Wow, really enjoyed the read, i look forward to seeing the result and hearing about how that diff is :)

[brosher]

For some reason I was thinking that the stock diff in the Touring was a lower gear ratio than 3.46:1. However, cleaning up the diff a little revealed 4 interesting characters: S, 4, 1 and 0, in that order. It's a limited-slip 4:10 rear.

BONUS!!! :D

[ILoveMPower]

Wow, wish my M30 was that clean :)

Did you paint the intake manifold? If so, what paint did you use?

[Mr Project]

Yes, a couple of years ago I painted the intake manifold, the valve cover, and the upper timing cover/thermostat housing. I used a single-stage gloss black automotive paint, I think it was Omni brand. It was a 'special' paint that was supposed to hold up to engine compartment conditions better. Worked pretty well, held up ok. I've been happy with it.

[Mr Project]

Quick update: I've been out of town this week, but I got a few things done today:

1 - Cleaned up and re-installed 4.10 diff.
2 - New fuel filter.
3 - Installed 19mm rear M5T sway bar.
4 - Installed new backup light switch and OEM short shifter with new bushings.
5 - Finished installing clutch pedal and return spring. Adjusted brake pedal for height.

Check out the new flywheel...can you guess which is the new 18lb lightened M30B34 flywheel, and which is the old 32lb dual-mass? I think with this and the temporary 4.10s it's going to be something of a hot rod. :D
http://img205.imageshack.us/img205/6041/img2431mediumvk8.jpg
http://img75.imageshack.us/img75/9641/img2429mediumcp5.jpg

[Robin-535im]

Re: 4.1o rear end... I think you will love 2nd through 5th but just giggle when you try to use 1st!

I've got the 3.91 and it's just about as much rear end as I think the M30 can push in 1st. You can break 'em loose most any time you're not going straight and you sure eat up the RPM's in a hurry! I have to shift to 3rd before 60 mph, but if you have a slight roll off the line starting in 2nd gives a nice pull once you get to 2k RPM or so.

[Mr Project]

Yeah, I expect that I'll be putting the 3.46 in in a fairly short amount of time...but I just have to try the 4.10. Yes, I'll probably be giggling in more than just 1st gear. :)

[Mr Project]

Well, I thought I had a 'before' picture, but I guess I don't. You'll have to take my word for it that it looked like 2 or 3 people had been murdered and then transported in the back of this car 5 years ago. It was disgusting....filthy and stained beyond belief.

After literally 3 rounds of carpet cleaning, and then 3 rounds of steam cleaning, here's the cargo area panels. I had them all out to do the rear suspension install, so I got them all put back in last night. It looks better in pictures than in person, but it's a huge improvement, anyway.

http://img213.imageshack.us/img213/135/img2486mediumqx4.jpg

I also got the A/C evap. cleaned up and hopefully will be able to re-assemble the lower dash area where I replaced the heater core.

Goal for this weekend will be setting the engine/tranny back in the car and getting started on the wiring.

[ILoveMPower]

Awesome man! Interior is looking gorgeous, trust me I can imagine what it looked like before.

Keep up the good work!

[Mr Project]

Thanks, cleaning the carpets gave me something to do while watching Season 2 of '24' with my wife. :)

I really need to get this project done so I can get the garage cleaned out and get back to the Corvair. The paint work on that car will be done in the next few weeks!

[rreimund]

http://img213.imageshack.us/img213/135/img2486mediumqx4.jpg



OMG - Touring Porn!..

That picture SO makes me want to get a wagon for my next purchase.. I know having that extra space would help immensely with all of the baby stuff we lug around these days. I'm hoping to hold onto my 535i sedan until I can afford to pick up a nice LeMan's Blue E39 M5.. It's a shame we don't get decent manual wagons here in the US. BAH!

nice project.. can't wait to see her done.:D

[Mr Project]

Ok, I apologize for the lack of detail lately, but I've been pushing pretty hard to get this thing done.

Over the weekend I made a little progress that was a big psycological step forward...I had the engine in and the car rolling around on the ground on all 4 wheels. Pretty dang close to the ground, too. :) That Koni/Eibach/3mm combo is going to look pretty good, I think.

http://img126.imageshack.us/img126/8606/img2521smallnn6.jpg

Here is the short version of tonight's progress:

http://img151.imageshack.us/img151/9863/img2544mediumbt8.jpg

1 - Installed heater valve assembly
2 - Lengthened coolant level sensor wiring from M50 harness to reach M30 sensor
3 - Finished routing and connecting all wiring other than lights and hood stuff on front end
4 - Hooked up and sealed all cooling system hoses other than radiator itself
5 - Hooked up all PS system hoses other than final cooling lines
6 - Installed front radiator support

I was going to install a block heater while I was doing all this, but getting the project done as quickly as possible is taking priority. Tomorrow I'll drop off my A/C lines to be rebuilt, and then pick up the parts I need to fix the exhaust and replace the center support bearing before re-installing the driveshaft.

There's a pretty good chance I'll have it running this week, if I don't run into any big snags.

[callen]

how many times did I want a 535 touring.....I'm thinking..you get good at this...and start turn keying these boys......whats it worth to you....10K?:)

[Mr Project]

Well, I guess Brandon J hates me for not making my own website for this, but here I go anyway. :)

The driveshaft center support bearing turned out to be more of a pain in the butt than I expected. I don't know what I expected it to be, but it took over an hour and a half to get the bolt removed, get the old bearing pressed out, and get the driveshaft re-assembled.

Once again the little shop press in the basement came to the rescue, after I fabbed up a couple pieces of angle iron and a C-clamp to serve as an arbor. It took some extensive fiddling, but it came off.

Tonight's progress:

1 - Center support bearing replaced
2 - Corner of fender roughly straightened and primed (had a nice ding in the front corner, I just want to make it weather proof for now)
3 - Cooling, PS systems finished up
4 - A/C condensor installed
5 - Headlights and corners installed.
6 - Bolted up tranny linkage
7 - Sold Volvo to little brother

http://img233.imageshack.us/img233/7558/img2547smallrk1.jpg

Tomorrow I should be able to do the driveshaft and exhaust, plus my A/C lines should be done, so I'll be able to get those installed and re-install the bumper/grill/hood as time allows. If the new A/C drier I ordered comes in a reasonable time, it's not too far-fetched to think that I'll be driving it on some shake-down runs at some point this weekend.

[aston_jag_tech]

Looking great, I cant wait to see the finished product!!

[brosher]

Now it's starting to come together! That thing is gonna be a blast to drive. :D

[Mr Project]

THWARTED!

:( :( :mad

Well, I screwed myself by mentioning the snag. The clutch master cylinder is shot. After bleeding probably 2 pints of fluid through it, and getting pretty good fluid flow, there is NO pressure being exerted on the pressure plate assembly.

I'll be calling BMA in the morning, it doesn't look like I can get one here by Saturday without spending a ton of money, so this weekend will probably be out in terms of the maiden voyage. Hopefully it will run, but I won't be doing any burnouts.

http://img206.imageshack.us/img206/9489/img2553mediumyk3.jpg

Front end is back on, exhaust is on, A/C is just wating for a bolt and a new drier.

[New Owner 95 E34]

Oh no! Where is the rest of the project posted?? I have been totally consumed with reading your thread... and I feel so unfulfilled! Please... tell me where I can see the rest!!

[Mendozart]

Good things come to those who wait. Sorry to hear of your delay. I can't wait till you drive it. I've been so impressed and have always looked forward to your updates.

[New Owner 95 E34]

Oh no! Where is the rest of the project posted?? I have been totally consumed with reading your thread... and I feel so unfulfilled! Please... tell me where I can see the rest!!

Don't pay any attention to the "new guy"... he's just figuring out how to tell when a message was posted.

Guess I'll wait patiently with everyone else for the saga to continue!

[Mr Project]

Sorry if I seem a little worked up. I'm up against the wall because the Corvair is coming back soon with new paint, I've sold my current DD, and I've been getting nasty phone calls from my credit union wanting the title to the Touring, which I can't get transferred until I can drive the car to the DMV for the out-of state title inspection.

So I really want to get this thing on the road!

The really weird thing is that I went out to the car this morning and it almost feels like the clutch pedal is doing something now. All it did was sit overnight....not sure why that would help anything.

[Mr Project]

IT LIVES!

I just made a lap of the neighborhood under M30B35 power! Lots of assembly and cleaning left, especially on the inside, before it's really 'streetable', but it moves without leaving a trail of parts or fluid behind, and so far makes pretty much the right noises!

[e39dream]

sweet!

[genphreak]

It's one of the best threads I've read in a while; a memeber really doing something worthwhile and well. Good work!!!

It's interesting how the debt collectors add a certain 'suspense' to the story... :D and far better than a Hollywood movie script!

[Mr Project]

Heh, yes, I guess my life is just full of drama. :)

Here's a couple of celebratory pictures: after just driving it a few blocks, the suspension settled about 3/4" more than what you see here...it's getting pretty low.

http://img137.imageshack.us/img137/8830/img2590mediumyt7.jpg
http://img137.imageshack.us/img137/8397/img2598largeez5.jpg

[Elekta]

****in dynamite dude. I am sick about my 530 now with a dying tranny and my wife's 535iA just sitting there with a for sale sign on it for $5k.

There is just no swapping her 3.5 i6 into my 3.0 v8 engine bay without major financial ram's

I need a plan to juice my motor and get a stick in there, or I may just totally say **** it and get that 94 silver M5T that Zaraska found for me in Europe with the blue seats. If I could just get $11k for my tourer, I'd be a 1/3 the way there. How will I ever find another fool such as me?

I am dreamin. Well, at least I whacked a few clay targets today, and am now into my second snow cone of ice cubes covered with some famouse grouse.

Love that gap in the front and congratulations.

Memo to Scott H. My lower M5 door pieces are finally in. Do you still want those rubber ones?

ps; if anyone hasn't realized it yet, touring's rule

[brosher]

That thing looks killer. I really like those wheels on the touring. Now that it moves, should be motivation enough to get the rest bolted on. Should be a blast of a DD.

[Paul in NZ]

thats a great job ....
what size are the wheels,looks like the rears are smaller than the fronts....
optical illusion.
Looking at the pics of the cleaned up interior you can see the tourings would be a very versatile vehicle!

[Mr Project]

The wheels are 16" E60 take-offs. I didn't think there were any E60 wheels that would look good on an E34, but I kinda like these.

[Jon K]

ok now boost it

[Mendozart]

Congratulations! Glad to see it made it on the road. I really want to replace my 4Runner with a touring.

[Mr Project]

Drove it to work all week, and spent today cleaning it up, it's more dramatic in person.

Before:
http://img180.imageshack.us/img180/8320/img2642beforesz3.jpg

After:
http://img182.imageshack.us/img182/2120/img2654largeco6.jpg

[Elekta]

nice

[Mendozart]

Well done! No problems during the week?

[Mr Project]

No, it runs great, no issues other than A/C and a hot start problem....usually have to crank it twice to start when hot. I need to move the check valve over from the sedan.

Found out it gets pretty healthy second-gear scratch, too. :D

[Dark Helmet]

I got a ride-along this AM... heeheehee... she pulls very well... VERY well.

[Sweetwater]

Just a beautiful thread....and a very nice piece of work.


If I had half the skills and any of the tools, I still would have to find the time to accomplish anything like it.

Thanks for the write-up.

[Mr Project]

Here's why I've been quiet lately...I've been pretty busy. My sister won on a reality TV show called Home Team...the Touring will even get some screen time!

http://www.journalstar.com/articles/2006/09/04/top_story/extras/doc44fb79ac0ad1a075273501.txt

[Thayne]

Wow its looking great! :D

[Johntee540]

That looks like my car! - JT

[ILoveMPower]

Island green? M30? Manual? Touring?

Goddamn, I don't think it gets any better :D

As I've said before, incredible work, very inspiring, and a job well done!