1984 635CSi (UK) project

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daharro
Posts: 20
Joined: Sat Feb 13, 2016 9:29 pm

1984 635CSi (UK) project

Post by daharro »

New member here, had the 6er for about 6 months and haven't been able to get too much done to it yet.

So far:
  • Bilstein B6 front dampers
  • front wishbones
  • top mounts
  • front brake e34 530 conversion
  • SI Board bypass
Immediate work
  • RUST!
  • Manual conversion
  • wiper motor replacement
  • blower fan replacement
I've just about got all the bits required for the manual conversion now, so i'll be ripping the manual box out soon. Whilst im under there i'll be getting to grips with the worst of the rot, hopefully its not too horrendous. Body work is reasonable (paint is shocking but no real corrosion, just small pockets in the usual places).

Annoyingly the only photo I can find at the moment is of its wheel arch, I'll get some more up soon!

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daharro
Posts: 20
Joined: Sat Feb 13, 2016 9:29 pm

Re: 1984 635CSi (UK) project

Post by daharro »

Well it's started. Drove it home so I can work on it, eventful drive involving a breakdown in a service station due to a dead battery and a big pool of fuel due to a knackered fuel pump gasket on the tank.

Stripped the carpet out of the front t survey the rust and I'm pleasantly surprised. Lots more good metal than expected.

The inner sill on the driver's side needs replacing, the two front corners in the footwells are gone and the round covers have rusted away and were being held in with sealant.

Lots more underneath to do, one if not both chassis legs need doing. But overall pretty good!
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wattsmonkey
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Location: Cheltenham, U.K.

Re: 1984 635CSi (UK) project

Post by wattsmonkey »

That looks pretty good to me: nice find!

Rob
"Most of it necessary; all of it enjoyable." LJKS
'84 635CSi, dogleg...itbs and supercharger????? Eaton Mess
daharro
Posts: 20
Joined: Sat Feb 13, 2016 9:29 pm

Re: 1984 635CSi (UK) project

Post by daharro »

Got a chance to cut out some rot today. Passenger side footwell is free from rot and I've got a panel ready to go in. Not going to look in any way factory but it'll be nice to have the first bit of rust gone. Looked at the back of the wing too and it looks in good condition. Dunno where the cars been stored but it's done it good!

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Chassis rail needs a bit of work too.

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daharro
Posts: 20
Joined: Sat Feb 13, 2016 9:29 pm

Re: 1984 635CSi (UK) project

Post by daharro »

A small amount of progress being made! The rust to metal ratio is being slowly reduced in favour of the metal...
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daharro
Posts: 20
Joined: Sat Feb 13, 2016 9:29 pm

Re: 1984 635CSi (UK) project

Post by daharro »

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As you can see, it ain't pretty but it'll get it through an Mot and back on the road!
alabbasi
Posts: 159
Joined: Wed Aug 14, 2013 3:33 am

Re: 1984 635CSi (UK) project

Post by alabbasi »

Great effort. The hard thing about rust is that the more you cut away, the more you find. I've often thought about shipping the rust free German bodies that I usually scrap over here back to Europe. I've asked around however but have not gotten much by way of positive feedback.
With best regards,
Al
85 M635, DFW, TX
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Ralph in Socal
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Re: 1984 635CSi (UK) project

Post by Ralph in Socal »

alabbasi wrote:Great effort. The hard thing about rust is that the more you cut away, the more you find. I've often thought about shipping the rust free German bodies that I usually scrap over here back to Europe. I've asked around however but have not gotten much by way of positive feedback.
It will happen eventually. I'm saving e10 e12 e21 e24 and e28 shells for the occasion. The time will come where the Brits and Aussies (and probably the Germans also) will have little metal to work with and shipping a rust free shell will be more cost effective (and more structurally sound) than fixing existing.

BTW Alabbasi - are you the same chap with the you tube vid of the MBZ 6.3?

And to the OP - agreed that yes, great effort and Keep On....

Ralph
There is a very fine line between "Hobby" and Mental Illness.

85 635csi Zinno Auto
84 528i Euro
83 635 Euro Arktik
81 528i Kastanien 5-speed
88 528e Bronzit (Granpa Car)
86 535i Auto (For Sale)
81 633 csi (retired)
alabbasi
Posts: 159
Joined: Wed Aug 14, 2013 3:33 am

Re: 1984 635CSi (UK) project

Post by alabbasi »

Ralph in Socal wrote:BTW Alabbasi - are you the same chap with the you tube vid of the MBZ 6.3?
Maybe :) I need to get back on that, I keep getting distracted by E12's
With best regards,
Al
85 M635, DFW, TX
daharro
Posts: 20
Joined: Sat Feb 13, 2016 9:29 pm

Re: 1984 635CSi (UK) project

Post by daharro »

Been a long time, best update you!

So I've got the structural welding finished. Both chassis rails, most of the floor to the inner still on the driver's side and the front edge of the rear wheel arch inside and out. Oh and both footwells! But it's done!

Also done...

-front shocks and all connecting bushes.
-rear dog bones
-manual conversion

Plus lots of niff naff stuff.

Loads to do, but notably it now has an MOT! Whoop!
wattsmonkey
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Location: Cheltenham, U.K.

Re: 1984 635CSi (UK) project

Post by wattsmonkey »

That's excellent news! Congratulations.

Nothing inspires more than actually driving the thing, especially once you do the manual conversion.
"Most of it necessary; all of it enjoyable." LJKS
'84 635CSi, dogleg...itbs and supercharger????? Eaton Mess
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