My Jagermeister replica Race Car Project

Document your Sixer project here.

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peterpilot
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Location: Johannesburg South Africa

My Jagermeister replica Race Car Project

Post by peterpilot »

Hi Guys,
It's been a long time since I was on the site as I have been busy bringing an old rusty 1977 shark from the dead and building my replica.
When I am done before the end of the year I promise to start producing those RHD Exhaust Headers that a few guys were asking about.
I will post some pictures soon and show what has been done thus far.
I have done a tremendous amount of work over the past two years getting the bodywork ready.
The left rear quarter had to be replaced, I replaced the whole rusty floor with a series two floor and used the rear suspension from this donor car too.
The front end is a combination of the E12 cross member, my own lower control arm system and the E28 based struts and hubs.
The lower rear sills were rusted and I rebuilt those both sides.
The roll cage is done and I'm just about finished with the paintwork.
It will be nice to have a race car to join my two road Sharks.
Last edited by peterpilot on Mon Jun 22, 2015 9:47 pm, edited 1 time in total.
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
GazM3
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Post by GazM3 »

Sounds an exciting project. Can't wait to see pics of it.
BMW’s
84 E24 M635csi
90 E34 M5 3.6
94 E34 540i/6 SC E85
97 E36 M3 euro SC U/C
97 Z3 2.8 widebody

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biggles
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Post by biggles »

Very keen to see the progress:)

I have since parted with my shark:( I was transferred to Namibia for a year and did not fancy the chances of it starting again after standing for a year.

New owner has pulled it back to bare shell and last I heard a V8 was being shoehorned in...
81 BMW 635csi RHD Euro manual.
02 M5
02 MCoupe
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peterpilot
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My Jagermeister replica Race Car Project

Post by peterpilot »

Hi Guys, here are some early stage pics.
Attachments
DSCN0854.jpg
DSCN0854.jpg (66.99 KiB) Viewed 16083 times
DSCN1084.jpg
DSCN1084.jpg (77.99 KiB) Viewed 16083 times
IMG_0540.JPG
IMG_0540.JPG (58.93 KiB) Viewed 16083 times
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
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peterpilot
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My Jagermeister replica Race Car Project

Post by peterpilot »

Some more early work......
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This left rear quarter was full of body filler.so I decided to remove it completely before sand blasting.
This left rear quarter was full of body filler.so I decided to remove it completely before sand blasting.
DSCN1146.jpg (80.36 KiB) Viewed 16078 times
found a donor car and used a good rear section.
found a donor car and used a good rear section.
DSCN1162.jpg (64.22 KiB) Viewed 16078 times
not sure how the front cross member got damaged, but decided to make a new one
not sure how the front cross member got damaged, but decided to make a new one
IMG_0446.JPG (69.42 KiB) Viewed 16078 times
more rust cut out and rebuilt
more rust cut out and rebuilt
IMG_0452.JPG (59.26 KiB) Viewed 16078 times
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
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peterpilot
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My Jagermeister replica Race Car Project

Post by peterpilot »

early bodywork continued.........
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cross member in place
cross member in place
IMG_0457.JPG (86.48 KiB) Viewed 16075 times
lower left rear section
lower left rear section
IMG_0435.JPG (52.94 KiB) Viewed 16075 times
left rear
left rear
IMG_0443.JPG (42.29 KiB) Viewed 16075 times
both of these lower rear sections were rotten
both of these lower rear sections were rotten
IMG_0479.JPG (52.83 KiB) Viewed 16075 times
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
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peterpilot
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My Jagermeister replica Race Car Project

Post by peterpilot »

.....pics continued, sorry about the order, but sure you can work it out.
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battery area was rotten.....
battery area was rotten.....
IMG_0483.JPG (53.06 KiB) Viewed 16070 times
IMG_0481.JPG
IMG_0481.JPG (45.67 KiB) Viewed 16070 times
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
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Hefeweizen
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Post by Hefeweizen »

Awesome! Looking forward to the next series!
Rainer
03 330Xi (DD)
85 635CSi (RIP 3 May 19)
80 633CSi (Red Euro, Project)

"If you think a good European mechanic is expensive, try a bad one!"
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Da_Hose
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Post by Da_Hose »

That is some really impressive work. =D>

Keep em coming!

Jose
1987 M6 - My dream car
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Ozibimmer
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Post by Ozibimmer »

coming along nice mate
_________________________
77 E3 3.0SI
77 E24 633CSi
78 E23 728i
79 E24 633CSi
80 E24 635CSi
82 E24 635csi Race Car Build (Schnitzer Replica) viewtopic.php?t=21792
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85 E30 JPS
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sansouci
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Post by sansouci »

Stupid question from a noobie. Do you weld through the primer or do you have to grind down to bare metal?
--Ken
Sansouci
84 E24 633Csi Auto, Bronzit/PearlBeige 6997510
93 E32 740il M60 Auto, Alpenweis/Ultramarine
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peterpilot
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Welding over primer

Post by peterpilot »

Before welding painted steel, even if is just a primed surface, yes you do need to clear the paint before welding. It is possible to weld through the painted surface, but it will never be as nice a weld as the paint contaminates the welding process as the paint burns.
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
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peterpilot
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My Jagermeistger Replica Race Car Project

Post by peterpilot »

Modifying the 1977 body to take a post 1982 rear bumper, Euro spec.
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....used old lower bumper section
....used old lower bumper section
IMG_0525.JPG (59.53 KiB) Viewed 15745 times
IMG_0520.JPG
IMG_0520.JPG (63.05 KiB) Viewed 15745 times
Last edited by peterpilot on Sun Jun 21, 2015 7:11 pm, edited 1 time in total.
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
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peterpilot
Posts: 122
Joined: Wed Apr 13, 2011 8:41 am
Location: Johannesburg South Africa

My Jagermeistger Replica Race Car Project

Post by peterpilot »

Rear body mods continued
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IMG_0497.JPG
IMG_0497.JPG (51.61 KiB) Viewed 15743 times
IMG_0506.JPG
IMG_0506.JPG (53.85 KiB) Viewed 15743 times
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
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peterpilot
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Joined: Wed Apr 13, 2011 8:41 am
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My Jagermeistger Replica Race Car Project

Post by peterpilot »

Rear body mods
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IMG_0513.JPG
IMG_0513.JPG (54.35 KiB) Viewed 15738 times
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
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kief
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Post by kief »

Ah man, nice to see the car up on a rotisserie, I really like race spec cars, and that's where I'm trying to take mine.

The old bumpers seem just so complicated, I'd probably rather mould some fiberglass bumpers in the future, but it'd be hard to beat the original euro spec bumpers.

German engineering definitely goes down to the smallest details, and that makes our lives more complicated when you tear into these cars.
1984 BMW 633CSi - traded for 1979 Yamaha XS750
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peterpilot
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Post by peterpilot »

Replacing a rusty floor and putting in an 86 series 2 floor from a donor wreck. I was going to patch my floor but then this donor shell came up and I grabbed it. bearing in mind, this car of mine is a 1977 model and the floor is substantially different.
Attachments
Much of the original floor was rusted so I cut it out
Much of the original floor was rusted so I cut it out
IMG_0668 1.jpg (68.64 KiB) Viewed 15628 times
donor floor
donor floor
IMG_0664 3 (1).jpg (84.79 KiB) Viewed 15628 times
donor floor
donor floor
IMG_0664 3 (2).jpg (84.79 KiB) Viewed 15628 times
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
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peterpilot
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My Jagermeister replica Race Car Project

Post by peterpilot »

Floor Transplant
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the old floor removed
the old floor removed
IMG_0704 5 (2).jpg (81.57 KiB) Viewed 15624 times
side attachments
side attachments
IMG_0704 5 (1).jpg (71.86 KiB) Viewed 15624 times
in place
in place
IMG_0723 6.jpg (81.96 KiB) Viewed 15624 times
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
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peterpilot
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My Jagermeister replica Race Car Project

Post by peterpilot »

After replacing the floor I had to patch a couple of rusty bits in the front area.
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Right side patch
Right side patch
IMG_0732 8 (1).jpg (61.75 KiB) Viewed 15622 times
Left side patch
Left side patch
IMG_0732 8 (2).jpg (72.76 KiB) Viewed 15622 times
All patched up
All patched up
IMG_0738 10 (1).jpg (67.39 KiB) Viewed 15622 times
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
Shipper 01
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Post by Shipper 01 »

nice. Put in the e28 chassis front and rear subframes as well as they are better track performers.
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peterpilot
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Post by peterpilot »

Hi Shipper,
Yes, I have used the series two rear sub frame and suspension and front struts. But I have used the series 1 front cross member and made my own adjustable control arms. Pics will follow. From experience, I have found the series two front end too sensitive, so I am much happier with this setup.
All will be revealed.......!
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
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peterpilot
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Location: Johannesburg South Africa

Post by peterpilot »

With the old floor removed, I had to make new beam attachment brackets.
Next was to beef up the Diff mounting. This area is a weak point in the early E24's.
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
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peterpilot
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Post by peterpilot »

Sorry, Let me reload those pics in a smaller format...
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Ipad Pictures 455.JPG
Ipad Pictures 455.JPG (67.71 KiB) Viewed 15565 times
IMG_0745.jpg
IMG_0745.jpg (61.03 KiB) Viewed 15565 times
IMG_0747.jpg
IMG_0747.jpg (64.14 KiB) Viewed 15565 times
IMG_0749.jpg
IMG_0749.jpg (59.46 KiB) Viewed 15565 times
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
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peterpilot
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Post by peterpilot »

Diff Brace and Front shock turret brace.
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Ipad Pictures 495.JPG
Ipad Pictures 495.JPG (55.28 KiB) Viewed 15563 times
Ipad Pictures 399.JPG
Ipad Pictures 399.JPG (69.14 KiB) Viewed 15563 times
Ipad Pictures 406.JPG
Ipad Pictures 406.JPG (57.63 KiB) Viewed 15563 times
This turret strut is attached to the modified bulkhead which is cut away on the right to allow exhaust hot air to exit through the  bonnet/hood vents.
This turret strut is attached to the modified bulkhead which is cut away on the right to allow exhaust hot air to exit through the bonnet/hood vents.
Ipad Pictures 411.JPG (62.43 KiB) Viewed 15563 times
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
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peterpilot
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Post by peterpilot »

The beefed up Diff mounting
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The 8mm pins extend from the beefed up diff mounting to attach to the plate in the boot/trunk which then is where the brace attaches.
The 8mm pins extend from the beefed up diff mounting to attach to the plate in the boot/trunk which then is where the brace attaches.
IMG_0753.jpg (63.16 KiB) Viewed 15560 times
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
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