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1988 635csi "Bring Her Back to Life"

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juiceof07
Posts: 84
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 » Sun Jun 26, 2016 4:17 am

Rear Deck Lid

Im stripping my old rear deck lid and getting it wrapped in carpet. There are a couple weak spots so i will temporally reinforce them with masking tape. I'll strengthen it with fiberglass and ensure it'll work. Everyone wants an arm and a leg for these things so I'm gonna handle this. Next in line...SPEAKER PODS! \:D/ \:D/
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Awesome Girlfriend Removing Staples
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Rear DeckLid Bottom
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Rear DeckLid Top
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Stripped Clean and Temporarily Reinforced
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STAY TUNED! More to come! Any tips just let me know!!
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725

juiceof07
Posts: 84
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 » Wed Jun 29, 2016 3:39 pm

Rear Deck Complete

Hey guys! I bought the fiber glass and the resin and applied it to the rear deck lids weak spots. Sanded down the excess fiber glass and it turned out pretty good in my opinion! I used an old rear deck lid carpet as a test fit and it turned out to be pretty accurate!
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Laid Fiberglass and resin
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Sand 1
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Sand 2
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Test Fit with old carped
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Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725

juiceof07
Posts: 84
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 » Wed Jun 29, 2016 3:45 pm

Speaker Pods

Decided to go ahead and tackle the speaker pods. This was actually a pretty interesting project. I sanded down all the pods and removed as much rust as I could. Used some epoxy to get the leather back on the metal rim as much as I could.
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Bought a pack of clamps and used them to hold the leather down while the epoxy cured.
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725

juiceof07
Posts: 84
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 » Wed Jun 29, 2016 3:58 pm

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After removing the clamps, I realized that the leather wasn't on the rim like I wanted it to. Sooooo...how do i fill in the gaps left by the shrunken leather? :-k :-k :-k ....I decided to use paintable clear caulk... 8-[ ...I know its pretty radical but I have nothing to lose with these speaker pods!
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I basically used the sealant to create the material in the void that the shrunken leather had created. I used the bottom edge of the metal frame and the outer edge of the leather as a reference point to create the mold..needs a little more work but I think I'm on to something here!! :mrgreen: ...The pods are going to get primed and painted so I figured this should actually work.

Let me know if you guys have any suggestion or better methods that I may not have thought of. Thanks!! :D :D
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725

juiceof07
Posts: 84
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 » Tue Jul 26, 2016 2:31 pm

Hey Ladies and Gents,

It's been a while since I've posted any progress. Turns out that I'm going to give in on the speaker pods that I tried to recover as they just won't cut it. I ordered all the remaining suspension components I need to get the car on the road and they should be here some time this week! I should be able to drive the car by the beginning of next month. I got a hell of a deal on some temp rims and tires off craigslist in town yesterday. I'll use these rims for the time being and purchase the anticipated Style 5's later on down the line. Updates coming soon!
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Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725

juiceof07
Posts: 84
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 » Thu Aug 11, 2016 4:30 pm

UPDATES!!!!! :D :D :D

The shark is off jack stands!!! I replaced the brake lines, rebuilt calipers and rebuilt the entire rear sub-frame. Turns out that my battery drain issue may have been tied to a bad battery. Car cranks up every time now. Also got some RC090 faces to go in my barrels. I'll get them refinished and they will be ready to go when the car is in its final stages. Ok here comes the pics!
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Rear Sub-frame together.
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Rear Sub-frame separated.
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Rear Sub-frame in the car!
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Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725

juiceof07
Posts: 84
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 » Thu Aug 11, 2016 4:37 pm

Some pics of her finally out the garage!
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The rear seems kind of high to me! Not sure if this car came with the correct shocks. Anyone have some used shocks for me to throw on let me know please!
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Snapped a picture before I left for work this morning! Ill keep you guys posted.
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725

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sansouci
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Re: 1988 635csi "Bring Her Back to Life"

Post by sansouci » Thu Aug 11, 2016 6:17 pm

I dunno about the ride height. I would think that it is determined by the springs, not the shocks.
Sansouci
84 E24 633Csi Auto, Bronzit/PearlBeige 6997510
93 E32 740il M60 Auto, Alpenweis/Ultramarine
60 535i M30 5-speed Green/Beige (crushed)
71 240Z 4-speed White/Blue (rusty & sold)
65 396 Chevelle 4-speed, Marina Blue/Black (stolen)

GRNSHRK
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Re: 1988 635csi "Bring Her Back to Life"

Post by GRNSHRK » Thu Aug 11, 2016 7:05 pm

Well, true Ken, but . . . :-k

Those rear struts appear to be white in color so I have no idea what brand they are, but Billstein have multiple grooves for the spring perch that permits changing the rear ride height =D>

I would get back under there and take a look, and if these are not adjustable, think I'd be looking for a set of Billy's, HD for stock springs and Sport for lowering springs [-o<
:mrgreen:
Bobbo
1980 633 CSi
Cypress Green/Pearl Beige
2011 F10 528i
2005 E46 330 Ci ZHP Cabrio
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You can never have too many BMW's

juiceof07
Posts: 84
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 » Thu Sep 01, 2016 3:38 pm

Hey guys! Been a while since an update but so much has happened! Here we go!

Apparently the rear shocks that were on the car didn't even line up into the mounting holes in the car. So I got some used shocks from another member and everything dropped right in. The rear seems to be a little more normal. The front end of the car was a disaster..borderline safety hazard...actually..it was just plain dangerous...ask me how I know... ](*,) ](*,) ](*,) . So I had it towed to a shop to get it examined as I have no experience with front end suspension work.
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Towing to Shop
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Tie rods were bad, lower strut mount screws were the wrong size... 8-[ ...idler arm was worn...sway bar connectors were bent...passenger control arm was done. Just a lot of bad things on that front end. While they were under the car I had them swap the oil and diff fluid. Car handles 500x better!!!! :mrgreen: :mrgreen:

Now that the front end was handled the car was still running super rich. So went ahead and ordered all the parts for a tune up. Plugs, Distributor cap, distributor rotor, all vacuum hoses, and welded the exhaust back on. Had to drop the gas tank, get all the rust out of the tank and, replace the fuel filter, and all evap hoses. Cleaned tank with some acid and reinstalled! After I did all that I've had an amazing experience in this car. The car is super responsive and no more misfiring! =D> =D> =D>

What came out the fuel filter.... [-( [-( [-(
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Dirty Fuel Filter
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Went to get the car aligned and ran into some terrible news! They were able to align the front end of the car but there aren't any adjustment points on the rear end to align the car. The car is out of alignment on the rear and the only way this can be fixed is with a toe and camber kit. This would require to remove the rear sub frame AGAIN!! ](*,) ](*,)
I have to purchase the kit or my rear tires will always wear prematurely. I'm super pissed about that! :twisted: :twisted: :twisted: :twisted:
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Alignment Shop
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I have some squeaking and I know its the power steering belt but I'm going to change all 3 belts hopefully this weekend if hurricane Hermaine doesn't ruin that for me. I also purchased a 3 spoke non air bag steering wheel from a buddy of mine and I'm going to install that. Been driving the car for the past 4 days! Runs like a champ.
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Riding Around Town!!
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This weekend I'm going to pick up a e23 745i Turbo Motor and all the turbo bits and slowly rebuild it!My plan right now it to keep driving the car around and give my e39 540i a well deserved rest! Ill keep you all posted as much as I can!!
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725

juiceof07
Posts: 84
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 » Wed Sep 07, 2016 3:49 pm

Turbo Motor Purchased

This weekend a couple friends and I went over to Jacksonville and pulled a turbo motor from an e23 745i. The turbo was destroyed and but all the other bits were in good condition. Looks like ill be looking to upgrade the turbo at this point.
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Pulled the motor and Transmission
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Towed the motor back to Tallahassee and dropped it in the garage.
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Motor in Garage
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Jacked the motor up on the hoist and began removing all the parts off the engine. Started at 11 AM and got done around 7PM. Learning so much about the components of this engine.
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Stripping Motor
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Got the motor on an engine stand and now I can start to rebuild everything and upgrade some components to build a reliable and powerful engine!

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Motor on Engine Stand
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Its time for me to swap out the belts on the car. One of them broke on me last night and I had to get towed to a friends house... :cry: :cry: . I'll try to keep you guys posted on all the progress.
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725

juiceof07
Posts: 84
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 » Wed Nov 09, 2016 5:18 pm

BACK TO WORK!

Greetings ladies and gents,

I have driven the shark around for about 2 months now and I'm ready to get back to work on it. The fuel pump is starting to give out so I decided that now is the time to go ahead and get back to the progress!

I went ahead and started to clear the interior and examine the body for rust and possible issues.
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Carpet Removed (Sound Insulation
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I removed the carpet and was left with the sound insulation. The sound insulation was wet and moldy and I had to rip it out of there. It was cracking all over and who knows how long its been like that.
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Driver Side Floor Panel
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Driver Side Panel was RUST FREE!!
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Passenger Side Floor Panel
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Passenger side was not looking as good as the driver. There was some surface rust and the floor board was bent.
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Passenger Rear Floor Panel
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This was the scariest of them all. I realized that this was the most molded and rusted point on the inside of the car. :roll: :roll: :roll:
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725

juiceof07
Posts: 84
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 » Wed Nov 09, 2016 5:32 pm

I had a buddy of mine come by and examine the floor boards and he told me it wasn't as bad as it looked. So I scraped up the layer of sound deadening and sanded down the surface rust and put a coat of OSPHO on the rust and everything started to look alot better! \:D/ \:D/ \:D/
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Pass. Rear Clean Up.
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The front passenger side need a little banging to go back into place. I got a piece of wood and a hammer and bent the floor board back as much as I could. Sanded it down and coated with OSPHO and it made a world of difference!
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Passenger Front Clean Up
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Here is a picture of all junk that made its way down from the blower motor (I think) into the car. These things were all over the place!
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Blower Motor Debris
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Next up is to remove the dash and inspect the firewall for and openings that could be leaking into the car! I'm going to purchase a bucket of "LizardSkin" and coat the inside of the car and the trunk area. Ill keep you all posted on my progress. Any words of advice, stickies, products, or sites that you all think would help me feel free to post!

Thanks!
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725

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zinnocoupe
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Re: 1988 635csi "Bring Her Back to Life"

Post by zinnocoupe » Sat Dec 10, 2016 5:28 pm

I just read your whole post. Nice work. Looks like a real challenge. Nice score with the 745 engine. Keep up the good work
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1979 Euro 635ci no longer a basketcase, just a running rust bucket!
1977 530i New addition ( nonrunner)
1987 635csi 60K KM Garage Queen

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M6smitten
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Re: 1988 635csi "Bring Her Back to Life"

Post by M6smitten » Sat Dec 10, 2016 7:24 pm

Luc,
You are absolutely kickin' ass! Wish we were neighbors. Keep posting your progress.
2011 1 Series M
1974 2002 Turbo
1987 M6 (2/87) - Sold
1984 M635CSi (10/84) - Sold
2012 335 xi
2009 328 xi

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Maverick
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Re: 1988 635csi "Bring Her Back to Life"

Post by Maverick » Sat Dec 10, 2016 8:28 pm

Great thread! Really enjoying the updates.. if I ever visit the states I'll pop to Tallahassee I'll bring tools, parts and a cooler :P
Keep up the good work!
1988 635csi highline shadowline Black/Grey leather ... tucked away for the winter being rebuilt! :-)

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Black-Out
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Location: Austin,Texas

Re: 1988 635csi "Bring Her Back to Life"

Post by Black-Out » Sun Dec 11, 2016 3:11 am

Wow amazing work! It's actually pretty funny how closely the problems your car had, compared to mine. I paid $700 for mine lol. I also had an E39 540i-6, But unfortunately it died a noble death when my 16 year old daughter was broad sided by a careless driver at an intersection. I know I can always get another E39, but man do I miss that car. It was just so damn clean.......

Anyways I gotta tell you, This is awesome, makes me feel like I'm not the only one going off the deep end trying to save a shark!
I also need to fix my rear dash and the sub frame bushings on mine. They aren't completely shot but they have definitely seen better days. I also had to replace pretty much every steering link, and control arm on the front end.....They were all shot lol......
How much of a pain was the bushing swap on the rear sub frame? I been dreading it.....

You're boosting your car and I been trying like hell to find the same engine for my 6 series. How much should I expect to pay for that engine? did you get a smoking deal on it or did you pay about average prices? I been tossing up the idea of just going with a bolt on turbo kit, but the lazy side of me thinks getting a factory turbo engine would have it's benefits as opposed to boosting the N/A engine..... I'm sure the boosted engine has stronger pistons to deal with the extra pressure but I would expect the rods and crank are the same as the N/A engine as BMW tends to way over engineer the bottom ends on these things. Just want to gain some insight on cost to get a better idea which route I should go cause I'm trying to budget build this thing.

Great job!

William-
"letting somebody borrow your car is like letting someone borrow your wife- You'll never know if you'll get it back with a rod thrown in it-"

Ron "Santa Claus" Schluettor

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sansouci
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Re: 1988 635csi "Bring Her Back to Life"

Post by sansouci » Sun Dec 11, 2016 4:47 pm

When you straightened the passenger floor board, look underneath as the dried, cracked undercoating is now a moisture trap.
By the way consider Dynamat to replace the interior soundproofing.

Great work. We need more restorations and fewer parts cars. It's all about the love.

Looks like you had some non-rent paying critters in your car.....
Last edited by sansouci on Mon Dec 12, 2016 9:39 pm, edited 1 time in total.
Sansouci
84 E24 633Csi Auto, Bronzit/PearlBeige 6997510
93 E32 740il M60 Auto, Alpenweis/Ultramarine
60 535i M30 5-speed Green/Beige (crushed)
71 240Z 4-speed White/Blue (rusty & sold)
65 396 Chevelle 4-speed, Marina Blue/Black (stolen)

juiceof07
Posts: 84
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 » Mon Dec 12, 2016 6:38 pm

zinnocoupe:
The challenge is extreme but I'm learning so much in the process which is exactly why I purchased this car. Could have got one for 4k and been in way better shape but where's the fun in that right? :D Thanks for the kind and motivating words!

M6smitten:
You could always move down here!! Lol. :lol: :lol: It's no where near as cold as it is in Denver right now and I could use some extra hands! Just sayin..But thanks for the motivation!

Maverick:
Tools and parts are always welcome and the cooler is NEVER denied!! I'll have a place for you to stay if you ever decide to make that trip! Thanks!

Black-Out:
The suspension was shot completely on this car but to be honest it's not that bad to replace! The subframe bushings were a PITA! I had to set them on fire and pound them out. Bought new bushings and dropped them off at a shop to be pressed in.

I got the engine, transmission, exhaust and all the turbo components for $700! I thought it was a hell of a deal but I think ill be going a different route and selling all the turbo components. If I'm not mistaken the turbo engine has lower compression and forged internals. The one thing I can tell you is decide what you want the end goal and purpose to be and it will direct you in the right direction to go!

Thanks for all the support and PM if you want to know any specific's. I'm learning but I'll give you whatever knowledge I have! :-)

sansouci:
Thank you for that! I didn't think of that! I was thinking of spraying the Lizard Skin, placing Dynamat in certain places in the car, and placing new neoprene rubber and closed cell foam back in the car. Would that be over kill? :-k
Thanks for the motivation! #SavetheSharks
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725

juiceof07
Posts: 84
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 » Mon Dec 12, 2016 6:49 pm

PROGRESS UPDATES!!!

After a couple days off I got back to work! Went ahead and removed the entire dash from the car and cleaned out all the excess debris that had made it under the dash over the years!
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I've decided instead of trying to purchase a new dash I'm going to clean this one up and flock the dash! The best $100 I can spend for this car. Purchased my dremel tool so I'm ready to open up those grooves! \:D/
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Here are the AC parts I removed out of the car. The AC wasn't functional when it was in the car. I want to know if there is any way to test the functionality of these things before I install them back in the car. If any one has any leads on this please let me know! Thanks!
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725

juiceof07
Posts: 84
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 » Mon Dec 12, 2016 6:57 pm

PROGRESS UPDATES!!!

Started on removing body parts!
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Created this windshield stand to hold the glasses but I turned out making it too wide so I used it for the trunk and hood!
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Removed the windsheilds!
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Rust Issues on the rear windshield... :|
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Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725

juiceof07
Posts: 84
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 » Mon Dec 12, 2016 7:05 pm

PROGRESS UPDATES!!!

Started removing the headliner...
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Sunroof is OUT OF WHACK! ](*,) ](*,) ](*,) ](*,) The motor is gone and the roof is off its track. The metal cable that pulls the sunroof in and out is coming out in the back of the sunroof assembly.... ](*,) ](*,) ](*,) .The sunroof is stuck open and the manual crank on the motor has no effect on the sunroof. At this point I don't even want to deal with it. My thoughts are to remove the sunroof and install a panoramic sunroof! The view from inside the 6 would be magnificent! \:D/ \:D/ Thoughts?
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Removed the rear windows...
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And after removing a lot of parts you must stop to organize and label all the inventory. Spent a whole day in my shed organizing and cleaning so I could get all the parts into it! 8) 8)
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Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725

juiceof07
Posts: 84
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 » Mon Dec 12, 2016 7:13 pm

SURPRISE UPDATE!!!

Was walking through my local junkyard and something caught my eye... 8-[ 8-[ 8-[ . I got a new toy for my birthday!! I've wanted this car for quite some time and its next on the project list but after dealing with the Shark I'm drawing the line here. If I get another car I will have to sell another one. Unless I get a bigger house and a bigger garage.... 8-[ 8-[ 8-[ 8-[ . The possibilities! I present....1986 Porsche 944!!
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I paid $600 for this car!! Motor is shot but I had no plans to keep it! Motor transplant is in the future plans. But the shark will get priority over her!

Thanks again guys!! I'll keep the updates coming as often as I can!
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725

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sansouci
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Re: 1988 635csi "Bring Her Back to Life"

Post by sansouci » Mon Dec 12, 2016 9:42 pm

So that's why there are multiple steering wheels in the shed....focus focus focus.....
Sansouci
84 E24 633Csi Auto, Bronzit/PearlBeige 6997510
93 E32 740il M60 Auto, Alpenweis/Ultramarine
60 535i M30 5-speed Green/Beige (crushed)
71 240Z 4-speed White/Blue (rusty & sold)
65 396 Chevelle 4-speed, Marina Blue/Black (stolen)

juiceof07
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Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 » Tue Dec 13, 2016 3:03 am

sansouci wrote:So that's why there are multiple steering wheels in the shed....focus focus focus.....
Lol! I'm trying so hard to stay focused! :lol: :lol: :lol:
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725

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