My Jagermeister replica Race Car Project

Document your Sixer project here.

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Ozibimmer
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Post by Ozibimmer »

Fantastic job with amazing fabrication skills.
Keep us posted
Cheers
Addam
_________________________
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
82 E28 JPS (1 of 2 Ever Built)
85 E30 JPS
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peterpilot
Posts: 122
Joined: Wed Apr 13, 2011 8:41 am
Location: Johannesburg South Africa

Jagermeister Replica Project

Post by peterpilot »

Starting with the roll cage
Attachments
Ipad Pictures 540.JPG
Ipad Pictures 540.JPG (57.86 KiB) Viewed 14635 times
Ipad Pictures 505.JPG
Ipad Pictures 505.JPG (48.17 KiB) Viewed 14638 times
Ipad Pictures 518.JPG
Ipad Pictures 518.JPG (76.04 KiB) Viewed 14638 times
Ipad Pictures 513.JPG
Ipad Pictures 513.JPG (59.28 KiB) Viewed 14638 times
Last edited by peterpilot on Sun Jul 05, 2015 8:51 pm, edited 2 times 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

Jagermeister Replica Project

Post by peterpilot »

More roll cage and other bracing
Attachments
Ipad Pictures 542.JPG
Ipad Pictures 542.JPG (61.55 KiB) Viewed 14633 times
Ipad Pictures 544.JPG
Ipad Pictures 544.JPG (50.88 KiB) Viewed 14633 times
Ipad Pictures 537.JPG
Ipad Pictures 537.JPG (71.63 KiB) Viewed 14633 times
Ipad Pictures 539.JPG
Ipad Pictures 539.JPG (42.01 KiB) Viewed 14633 times
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 Jagermeister replica Race Car Project

Post by peterpilot »

Roll cage cont.
Attachments
Ipad Pictures 532.JPG
Ipad Pictures 532.JPG (49.4 KiB) Viewed 14630 times
Ipad Pictures 533.JPG
Ipad Pictures 533.JPG (47.35 KiB) Viewed 14630 times
Beefed up Seat mountings
Beefed up Seat mountings
Ipad Pictures 548.JPG (36.4 KiB) Viewed 14630 times
6 Point Harness floor anchors
6 Point Harness floor anchors
Ipad Pictures 549.JPG (51.64 KiB) Viewed 14630 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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Location: PA, USA

Post by kief »

amazing work on the rollcage since I looked here yesterday. I need one of those, along with your strut braces.
1984 BMW 633CSi - traded for 1979 Yamaha XS750
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peterpilot
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Joined: Wed Apr 13, 2011 8:41 am
Location: Johannesburg South Africa

My Jagermeister replica Race Car Project

Post by peterpilot »

Time to start with the suspension.
Note that the rear end is entirely e28 based series 2 E24 and the front is a combination of the two. Series 1 cross member and steering but the struts are series two, so the steering arms on the bottom of the struts had to be extended to match the series 1 steering and idler arms.
Attachments
Front modified lower control arms. Notice the rearward anti-roll bar is the way Ive gone and picked up an X3 roll bar to do the job,
Front modified lower control arms. Notice the rearward anti-roll bar is the way Ive gone and picked up an X3 roll bar to do the job,
IMG_0919.jpg (80.98 KiB) Viewed 14675 times
Rear modified trailing arm.
Rear modified trailing arm.
IMG_0899.jpg (73 KiB) Viewed 14675 times
Rear subframe  modified bushes.
Rear subframe modified bushes.
Ipad Pictures 558.JPG (57.18 KiB) Viewed 14675 times
Modified front cross member
Modified front cross member
Ipad Pictures 560.JPG (47.73 KiB) Viewed 14675 times
Last edited by peterpilot on Sun Jul 12, 2015 8:20 pm, edited 4 times in total.
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
User avatar
peterpilot
Posts: 122
Joined: Wed Apr 13, 2011 8:41 am
Location: Johannesburg South Africa

My Jagermeister replica Race Car Project

Post by peterpilot »

More suspension mods
Attachments
Rubber bushes replaced with smaller diameter polyurethane bushes
Rubber bushes replaced with smaller diameter polyurethane bushes
IMG_0956.jpg (65.78 KiB) Viewed 14673 times
Ipad Pictures 558.JPG
Ipad Pictures 558.JPG (57.18 KiB) Viewed 14673 times
front cross member mods
front cross member mods
Ipad Pictures 562.JPG (59.78 KiB) Viewed 14673 times
.....more front cross  member mods
.....more front cross member mods
Ipad Pictures 563.JPG (63.19 KiB) Viewed 14673 times
Last edited by peterpilot on Sun Jul 12, 2015 7:58 pm, edited 1 time in total.
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
User avatar
peterpilot
Posts: 122
Joined: Wed Apr 13, 2011 8:41 am
Location: Johannesburg South Africa

My Jagermeister replica Race Car Project

Post by peterpilot »

Using an old side loader diff on the series 2 rear sub frame
Attachments
Ipad Pictures 581.JPG
Ipad Pictures 581.JPG (71.5 KiB) Viewed 14671 times
Ipad Pictures 554.JPG
Ipad Pictures 554.JPG (70.48 KiB) Viewed 14671 times
Ipad Pictures 555.JPG
Ipad Pictures 555.JPG (43.9 KiB) Viewed 14671 times
Rear Adjustment for rear camber and toe-in,
Rear Adjustment for rear camber and toe-in,
Ipad Pictures 575.JPG (63.93 KiB) Viewed 14671 times
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 Jagermeister replica Race Car Project

Post by peterpilot »

Repaired extensively cracked Dash
Attachments
IMG_1083.jpg
IMG_1083.jpg (61.23 KiB) Viewed 14670 times
IMG_1086.jpg
IMG_1086.jpg (68.39 KiB) Viewed 14670 times
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
User avatar
peterpilot
Posts: 122
Joined: Wed Apr 13, 2011 8:41 am
Location: Johannesburg South Africa

My Jagermeister replica Race Car Project

Post by peterpilot »

Filling in the sun roof, and then the painting begins.....
Attachments
IMG_0920.jpg
IMG_0920.jpg (65.77 KiB) Viewed 14668 times
roll cage painted first
roll cage painted first
IMG_0941.jpg (84.23 KiB) Viewed 14668 times
....then mask up the roll cage and begin with the interior
....then mask up the roll cage and begin with the interior
IMG_0953.jpg (73.61 KiB) Viewed 14668 times
IMG_0966.jpg
IMG_0966.jpg (69.72 KiB) Viewed 14668 times
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
User avatar
peterpilot
Posts: 122
Joined: Wed Apr 13, 2011 8:41 am
Location: Johannesburg South Africa

My Jagermeister replica Race Car Project

Post by peterpilot »

Painting the underside
Attachments
IMG_0978.jpg
IMG_0978.jpg (69.13 KiB) Viewed 14667 times
IMG_0988.jpg
IMG_0988.jpg (78.96 KiB) Viewed 14667 times
IMG_0984.jpg
IMG_0984.jpg (80.86 KiB) Viewed 14667 times
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
User avatar
peterpilot
Posts: 122
Joined: Wed Apr 13, 2011 8:41 am
Location: Johannesburg South Africa

My Jagermeister replica Race Car Project

Post by peterpilot »

Painting
Attachments
Engine Bay
Engine Bay
IMG_0961.jpg (75.47 KiB) Viewed 14666 times
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
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Tim Bradham
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Post by Tim Bradham »

Really nice build!
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hornhospital
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Post by hornhospital »

How'd you restore the dash? Not to interrupt your great thread, but there's many of us that would like to know.
Ken Kanne
'84 633CSi "Sylvia"; '85 635CSi "Katja";'85 325e "Hazel Ann"; '95 M3 "Ashlyn"
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tschultz
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Post by tschultz »

Also, I'd be interested in some details on the cage if you have any!
http://www.Drive4Corners.com
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'79 635CSi Revival
'80 635CSi
'83 633CSi Callaway Turbo continued as 1988 535is Turbo
SOLD: '81 635CSi/A
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TBM
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Post by TBM »

Me three on the Dash!!!
'84 M635csi
'86 Lotus esprit Turbo (sold)
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peterpilot
Posts: 122
Joined: Wed Apr 13, 2011 8:41 am
Location: Johannesburg South Africa

My Jagermeister replica Race Car Project

Post by peterpilot »

Hi Guys, please be patient regarding the dash repairs. I will come back to you with that. I need to take a pic of the rubber product I used.

I basically cut the cracks wider and at least 10mm deep to get rid of any curling of the skin and allow the filler product to have an anchor.
Bear in mind that the dash no longer has the leather look. I used my own paint technique with a flex agent added.

....Will give more details later. Cheers for now, Peter
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 Jagermeister replica Race Car Project

Post by peterpilot »

This is what I'm heading for....
Attachments
this is what it must look like......
this is what it must look like......
IMG_1196.jpg (76.93 KiB) Viewed 14047 times
E28 struts, E46 discs(Rotors)
E28 struts, E46 discs(Rotors)
IMG_1103.jpg (64.63 KiB) Viewed 14047 times
Fuel Tank under construction
Fuel Tank under construction
IMG_1180.jpg (70.57 KiB) Viewed 14047 times
FuelTank
FuelTank
IMG_1185.jpg (63.87 KiB) Viewed 14047 times
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
User avatar
peterpilot
Posts: 122
Joined: Wed Apr 13, 2011 8:41 am
Location: Johannesburg South Africa

My Jagermeister replica Race Car Project

Post by peterpilot »

Getting on with the paintwork.....
Attachments
Bumper bits, stripped of chrome , primed and ready for colour...
Bumper bits, stripped of chrome , primed and ready for colour...
IMG_1259.jpg (79.82 KiB) Viewed 14046 times
Bumper bits
Bumper bits
IMG_1163.jpg (71.41 KiB) Viewed 14046 times
front spoiler
front spoiler
IMG_1297.jpg (62.76 KiB) Viewed 14046 times
IMG_1176.jpg
IMG_1176.jpg (81.01 KiB) Viewed 14046 times
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
User avatar
peterpilot
Posts: 122
Joined: Wed Apr 13, 2011 8:41 am
Location: Johannesburg South Africa

My Jagermeister replica Race Car Project

Post by peterpilot »

Fitting the mechanicals
Attachments
motor first....
motor first....
IMG_1216.jpg (72.01 KiB) Viewed 14044 times
IMG_1221.jpg
IMG_1221.jpg (81.06 KiB) Viewed 14044 times
IMG_1224.jpg
IMG_1224.jpg (79.05 KiB) Viewed 14044 times
IMG_1237.jpg
IMG_1237.jpg (88.87 KiB) Viewed 14044 times
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
User avatar
peterpilot
Posts: 122
Joined: Wed Apr 13, 2011 8:41 am
Location: Johannesburg South Africa

My Jagermeister replica Race Car Project

Post by peterpilot »

More Mechanicals........
Attachments
Drive Shafts in, Propshaft in....
Drive Shafts in, Propshaft in....
IMG_1255.jpg (67.57 KiB) Viewed 14421 times
IMG_1149.jpg
IMG_1149.jpg (55.23 KiB) Viewed 14421 times
Brake Master cylinder and hydraulic booster in place.
Brake Master cylinder and hydraulic booster in place.
IMG_1161.jpg (72.33 KiB) Viewed 14421 times
IMG_1151.jpg
IMG_1151.jpg (61.29 KiB) Viewed 14421 times
Last edited by peterpilot on Sat Sep 05, 2015 5:49 am, edited 1 time in total.
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
User avatar
peterpilot
Posts: 122
Joined: Wed Apr 13, 2011 8:41 am
Location: Johannesburg South Africa

My Jagermeister replica Race Car Project

Post by peterpilot »

Cluster.....
Attachments
IMG_1201.jpg
IMG_1201.jpg (68.56 KiB) Viewed 14419 times
cluster complete...
cluster complete...
IMG_1249.jpg (66.17 KiB) Viewed 14419 times
Dash complete
Dash complete
IMG_1204.jpg (72.05 KiB) Viewed 14419 times
IMG_1168.jpg
IMG_1168.jpg (70.85 KiB) Viewed 14419 times
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
User avatar
peterpilot
Posts: 122
Joined: Wed Apr 13, 2011 8:41 am
Location: Johannesburg South Africa

My Jagermeister replica Race Car Project

Post by peterpilot »

Getting there......
Attachments
IMG_1176.jpg
IMG_1176.jpg (81.01 KiB) Viewed 14416 times
IMG_1200.jpg
IMG_1200.jpg (62.41 KiB) Viewed 14416 times
IMG_1291.jpg
IMG_1291.jpg (65 KiB) Viewed 14416 times
IMG_1286.jpg
IMG_1286.jpg (80.3 KiB) Viewed 14416 times
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
User avatar
peterpilot
Posts: 122
Joined: Wed Apr 13, 2011 8:41 am
Location: Johannesburg South Africa

My Jagermeister replica Race Car Project

Post by peterpilot »

Final stages
Attachments
IMG_1310.jpg
IMG_1310.jpg (68.11 KiB) Viewed 14414 times
IMG_1301.jpg
IMG_1301.jpg (64.22 KiB) Viewed 14414 times
IMG_1308.jpg
IMG_1308.jpg (65.95 KiB) Viewed 14414 times
IMG_1294.jpg
IMG_1294.jpg (66.38 KiB) Viewed 14414 times
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
User avatar
peterpilot
Posts: 122
Joined: Wed Apr 13, 2011 8:41 am
Location: Johannesburg South Africa

My Jagermeister replica Race Car Project

Post by peterpilot »

Getting ready for 30th August BMW Annual Club Cponcourse.
Attachments
Decals going on .....
Decals going on .....
IMG_1312.jpg (76.31 KiB) Viewed 14411 times
IMG_1316.jpg
IMG_1316.jpg (77.01 KiB) Viewed 14411 times
IMG_1327.jpg
IMG_1327.jpg (64.85 KiB) Viewed 14411 times
IMG_1325.jpg
IMG_1325.jpg (68.11 KiB) Viewed 14411 times
1981 635 CSI Euro Manual
1985 635 CSI Euro Manual
1998 540 I Steptronic
2004 K1200 RS
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