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1982 CSi Resto

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randall977
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1982 CSi Resto

Post by randall977 » Sun Jan 21, 2018 2:07 pm

Hi, just joined this forum having gleaned a lot of useful information since buying my E24 a few weeks ago - thank you!

I've always likes the 635 CSi, but was put off by the boy racers who tended to own them (here in the UK). As prices rise I thought I better get one and so got a project car. It's an early series 2 (1982), manual with dog leg, black Recaro, rear head rests, headlight wipers in Henna Red. I got it on the strength of its body work - only minor welding is needed around the rear lights and the ends of one sill. The previous owner evidently fitted my stereo type image and fitted a large sub woofer, many amplifiers, added M6 TRX alloys and painted out the chrome. It's been off the road for 9 years in a workshop where it accumulated a lot of dust and primer from nearby re-sprays - however, it polishes up well with much elbow grease.

My aim is to get the car in good mechanical order and return it to factory spec. So far I have done the following;

1. Replaced all discs, pads, flexi pipes and associated brake accessories.
2. Replaced the fuel lines with genuine BMW.
3. New fuel pump and filters, seals etc.
4. Near genuine rear exhaust box and mounts.
5. New gear linkages and stick.
6. New ignition switch.
7. Replaced heater valve, fan diode, temperature control joint and improved the fan.
8. New battery and tray.
9. Restored the interior - new carpet, including boot.
10. Batteryless SI board upgrade.
11. New genuine headlight wiper motors, washer motors etc.
12. New genuine BBS 14" alloys and tyres.
13. New radiator, hoses, restored thermostat housing etc.
14, New belts, improved the oil spray rail etc etc.
15. Replaced speed and pulse sensors.
16. Other bits and pieces....

I love the fact the BMW still supply most spares and I've also been using Wallothesch.

Still a lot to do - electric windows, sunroof, start the engine...hopefully the gearbox is okay...

Photos as found - last one is this now...
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Last edited by randall977 on Tue May 01, 2018 7:10 pm, edited 1 time in total.

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Re: 1982 CSi Resto

Post by hornhospital » Sun Jan 21, 2018 7:05 pm

Looks like she buffed up nicely!
Welcome to the insanity!
Ken Kanne
'84 633CSi "Sylvia"; '85 635CSi "Katja";'87 325is "Odette"; '93 325is "Elvira"; '95 M3 "Ashlyn"

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Re: 1982 CSi Resto

Post by tschultz » Mon Jan 22, 2018 12:27 am

Looks like an '83 with the Motronic fuel injection and later rear bumper.

Also it appears an e28 spoiler has been installed on the trunk instead of a correct E24 piece.

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Re: 1982 CSi Resto

Post by randall977 » Mon Jan 22, 2018 7:51 am

Thanks for the comments. Would love to sort the boot lid (trunk) spoiler out - bet that'll be difficult to source! What should the bumper look like - it's a series 2?

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Re: 1982 CSi Resto

Post by olympia57 » Mon Jan 22, 2018 5:30 pm

A heap of praise to you for saving and bringing it back from the brink.
I hate the way that the E24 and 28 have been bastardised and then cast aside when "fashion" moved to another marque.
Good luck to you ,there's nothing nicer than a (near) stock E24.
Look forward to seeing your progress.
Don
1981 635 series 1

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Re: 1982 CSi Resto

Post by wattsmonkey » Mon Jan 22, 2018 6:31 pm

Welcome! Is this the car from Swindon? If so, I've heard good things about the bodywork, which is always the biggest ballache. Recaros and dogleg always a winner. I'd bet yours has got the medium case lsd and light flywheel too if it's an '82.

Cheers,

Rob
"Most of it necessary; all of it enjoyable[!]" LJKS
'86 M635CSi #367 Bring the Noise.
'84 635CSi, dogleg fun

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randall977
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Re: 1982 CSi Resto

Post by randall977 » Mon Jan 22, 2018 10:31 pm

Thanks! Yes it's the Swindon one - I didn't want anything too far away and manual was a must. It's a very early series 2 so it has OBC, 218bhp etc - I found the build sheet behind the rear seat which confirmed that's it's still original spec. The body is surprisingly good - not sure why as I don't think the car has been cared for in recent years. I did find a few nice Genuine spares tucked away in the boot. I'm actually really enjoying the restoration so far - after working on 60's cars it's nice to have something where all the nuts and bolts still undo.

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Re: 1982 CSi Resto

Post by wattsmonkey » Tue Jan 23, 2018 7:44 am

Nice one!

I'm in the same boat as you with my project car in working out how best to "de-shadowline". I dare say you know your car would have had the (v cool imho) rubber boot spoiler?

I'm sure I've got spares of both sorts in the stash, give me a shout if you're ever in Cheltenham.

Cheers,

Rob
"Most of it necessary; all of it enjoyable[!]" LJKS
'86 M635CSi #367 Bring the Noise.
'84 635CSi, dogleg fun

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Re: 1982 CSi Resto

Post by randall977 » Tue Jan 23, 2018 9:50 am

Rob, i would be very interested in any spare spoiler you have! Just got the 1982 brochure today which shows the new series 2 - I can now see that the spoiler is totally wrong, rear bumper is right and it should have individual front fog lights (though I'm not keen on non integrated fogs!).

The main problem with blacked out ali-chrome is where the person who did it sanded the trim to get a key - the only option then is to replace or try and polish.

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Re: 1982 CSi Resto

Post by randall977 » Fri Feb 09, 2018 5:09 pm

Just an update on where I am with this one. Much work done on trying to start the engine - I think I'm nearly there! Interior pretty much ready. Electrics sorted. The clutch probably needs work - its a Getrag 5CR - am I right in thinking that the gearbox can be removed in two parts?

Eng1.jpg
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Whilst waiting for a new part I thought I would remove the NS wing as the bottom edge needs welding - pretty good underneath. Shouldn't the sunroof drain pipe protrude out of the hole in the sill?

Feb1.jpg
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Finally - how do you remove the plastic trim around the window...which I snapped taking the wing off!

Seats.jpg
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Last edited by randall977 on Tue May 01, 2018 7:11 pm, edited 1 time in total.

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Re: 1982 CSi Resto

Post by rattusM6 » Fri Feb 09, 2018 5:51 pm

Very cool, and welcome.

Regarding the trim, I will have the same dilemma on whether to keep the shadow line look or try and resort back to chrome.
Apparently some twat (oh wait that was me) decided 13 years ago that shadow line on a silver M6 was the way to go.
Of course now, I sort of regret the decision as chrome is now so much cooler.

Oh, and I love Henna Red!!!!!

Kev
Realised I was dyslexic whilst at a toga party dressed as a goat.
85 E24 M6 - 14 years
92 E30 M3 - 11 years now sold
06 E46 M3 - 2 years
13 Ford Grand C-Max, the family wagon
99 E36 323i Sport Touring - now sold
02 E46 Alpina B3 3.3 - 1.5 years

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Re: 1982 CSi Resto

Post by e24trapt » Fri Feb 09, 2018 6:28 pm

Gutter trim comes off in 3 pieces from fender to the back kink AFTER you pull the chrome first which you WILL NOT save. DIY restoration....ill get my popcorn ready.....electronics for engine you might as well switch to e34 style...atleast car will be guaranteed to run. But that is alot of work for someone that doesnt know the car. Good luck.
1991 Cadillac DeVille 4.9 V8 Daily Driver
-202hp @ 4400
-274ft/lbs @ 3100

1983 BMW 633csi N/A Beast (sold)

1989 BMW 635csi (future Turbo 6 speed)

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Re: 1982 CSi Resto

Post by olympia57 » Fri Feb 09, 2018 7:32 pm

Whilst waiting for a new part I thought I would remove the NS wing as the bottom edge needs welding - pretty good underneath. Shouldn't the sunroof drain pipe protrude out of the hole in the sill?


Sill.jpg


Yes it should but I'll bet yours is like mine was . I found the black factory plastic drain terminated inside the sill about three inches away from the exit hole. It clearly had never been long enough as both sides were identical so all those years the salty drain water from the sunroof had been dripping into both sills and then onto the floor seam. This little manufacturing failure probably resulted in the demise of many an E24.......
IMGP0714 (Large).JPG
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Access can be gained by removing the kick panel speakers and this will allow you to attach a suitable length of 1/2 inch plastic water pipe which in turn can be routed out of the manufactured hole .
010 - Copy - Copy (Large).jpg
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Don
1981 635 series 1

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Re: 1982 CSi Resto

Post by randall977 » Fri Feb 09, 2018 9:27 pm

Thank you all and in particular Don - very useful info and tip - nice brakes btw. I know the electrics can be a bit of a headache but for a 36 year old car I'm surprised anything works - I mean the OBC works fine which is amazing.

Anyone know if the Getrag 265 5CR can come out in two pieces?

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Re: 1982 CSi Resto

Post by rattusM6 » Fri Feb 09, 2018 9:47 pm

randall977 wrote:
Fri Feb 09, 2018 9:27 pm
Thank you all and in particular Don - very useful info and tip - nice brakes btw. I know the electrics can be a bit of a headache but for a 36 year old car I'm surprised anything works - I mean the OBC works fine which is amazing.

Anyone know if the Getrag 265 5CR can come out in two pieces?
As far as I am aware with this gear box you can disconnect from the bell housing first which is what I used to do with the E30 m3.
Hopefully you will find just 4 large bolts holding the box to the bell housing, then quite a few torx bolts holding the bell housing to the engine block.
Of course getting under the car to have a look is the only way to confirm this or check on ETK if you have a copy handy.

Note, for the standard 5 speed on the M6 the gearbox and bell housing is unfortunately one piece.

Oh, if you can remove the gearbox from the bell housing - for the 2 top bolts you MAY need to customize a ring spanner by shortening it (basically a stubby ring spanner so it will fit in the tunnel) and then with the aid of another ring spanner get purchase to crack the bolts. Anyway you will soon find out.

Kev
Last edited by rattusM6 on Fri Feb 09, 2018 9:57 pm, edited 1 time in total.
Realised I was dyslexic whilst at a toga party dressed as a goat.
85 E24 M6 - 14 years
92 E30 M3 - 11 years now sold
06 E46 M3 - 2 years
13 Ford Grand C-Max, the family wagon
99 E36 323i Sport Touring - now sold
02 E46 Alpina B3 3.3 - 1.5 years

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Re: 1982 CSi Resto

Post by wattsmonkey » Fri Feb 09, 2018 9:54 pm

Yes: absolutely remove in two pieces. Crow's foot wrench makes it easier.
"Most of it necessary; all of it enjoyable[!]" LJKS
'86 M635CSi #367 Bring the Noise.
'84 635CSi, dogleg fun

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rattusM6
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Re: 1982 CSi Resto

Post by rattusM6 » Fri Feb 09, 2018 10:00 pm

wattsmonkey wrote:
Fri Feb 09, 2018 9:54 pm
Yes: absolutely remove in two pieces. Crow's foot wrench makes it easier.
Or as Rob mentioned, a Crows foot may be the answer :D
Realised I was dyslexic whilst at a toga party dressed as a goat.
85 E24 M6 - 14 years
92 E30 M3 - 11 years now sold
06 E46 M3 - 2 years
13 Ford Grand C-Max, the family wagon
99 E36 323i Sport Touring - now sold
02 E46 Alpina B3 3.3 - 1.5 years

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randall977
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Re: 1982 CSi Resto

Post by randall977 » Fri Feb 09, 2018 10:00 pm

Thank you - that's great news as gearbox removal is my least favourite job.

Another question if I may - can the wing be removed without removing the window surround trim? I wasn't able to clear the front baffle and hence broke the surround when I lifted the wing off to remove it.

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rattusM6
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Re: 1982 CSi Resto

Post by rattusM6 » Fri Feb 09, 2018 10:06 pm

randall977 wrote:
Fri Feb 09, 2018 10:00 pm
Thank you - that's great news as gearbox removal is my least favourite job.

Another question if I may - can the wing be removed without removing the window surround trim? I wasn't able to clear the front baffle and hence broke the surround when I lifted the wing off to remove it.
Mmmm, to be honest I removed all the trim beforehand as it made sense to do so - before removing the wings.
Realised I was dyslexic whilst at a toga party dressed as a goat.
85 E24 M6 - 14 years
92 E30 M3 - 11 years now sold
06 E46 M3 - 2 years
13 Ford Grand C-Max, the family wagon
99 E36 323i Sport Touring - now sold
02 E46 Alpina B3 3.3 - 1.5 years

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randall977
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Re: 1982 CSi Resto

Post by randall977 » Fri Feb 09, 2018 10:08 pm

Not all of the chrome is available and I'm told (in this thread and I had a go myself) that it can't be removed without destroying it - or can?

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rattusM6
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Re: 1982 CSi Resto

Post by rattusM6 » Fri Feb 09, 2018 10:33 pm

randall977 wrote:
Fri Feb 09, 2018 10:08 pm
Not all of the chrome is available and I'm told (in this thread and I had a go myself) that it can't be removed without destroying it - or can?
I managed to remove all my trim undamaged (maybe a couple of kinks that can be repaired) but it took a lot of friggin time, patients, some swearing and above all luck.
Realised I was dyslexic whilst at a toga party dressed as a goat.
85 E24 M6 - 14 years
92 E30 M3 - 11 years now sold
06 E46 M3 - 2 years
13 Ford Grand C-Max, the family wagon
99 E36 323i Sport Touring - now sold
02 E46 Alpina B3 3.3 - 1.5 years

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Re: 1982 CSi Resto

Post by randall977 » Fri Feb 09, 2018 10:44 pm

I might have another go then - at £100 a piece and one section NLA I'll have to be very careful!

Below is some fun I had with the SI board before buying a new one - which works great - would love to know how to reset the LED indicators...

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Last edited by randall977 on Thu Sep 06, 2018 9:15 pm, edited 2 times in total.

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Re: 1982 CSi Resto

Post by olympia57 » Fri Feb 09, 2018 11:46 pm

randall977 wrote:
Fri Feb 09, 2018 10:00 pm
Thank you - that's great news as gearbox removal is my least favourite job.

Another question if I may - can the wing be removed without removing the window surround trim? I wasn't able to clear the front baffle and hence broke the surround when I lifted the wing off to remove it.
I had no problem removing both front wings on my series one car with the gutter trim in situ but the front tongue is shorter and smaller on the earlier cars. I'd be surprised if you did have to remove the trim though. I'd place the ns wing back on and try manoevering it upwards at the front first and then pulling it forward. If the front splash guard is original it shouldn't be touching the wing the profile leaves a small gap between the two (aĺowing all the crap to get in and rot the frontal part of the wing.....) Not sure of series two cars but series one has two small self tapping screws securing the tongue to the wing , if fitted did you remove them ?
1981 635 series 1

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Re: 1982 CSi Resto

Post by wattsmonkey » Sat Feb 10, 2018 12:34 pm

You can just about squeeze wing past gutter trim, but you will almost certainly crack the rear of it.
"Most of it necessary; all of it enjoyable[!]" LJKS
'86 M635CSi #367 Bring the Noise.
'84 635CSi, dogleg fun

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Re: 1982 CSi Resto

Post by randall977 » Sat Feb 10, 2018 5:01 pm

Prised the window surround chrome strip off - once started it wasn't too bad but did bend it a bit - might just buy a new replacement.

As predicted the sunroof hose on the OS was just the same plus a small rust hole into the drivers foot well - which probably explains why it was wet when I got it. This hose issue is up there with the oil spray bar - a must when doing a resto. I cut the hoses short through the speaker openings and have ordered joiners and silicone hose extensions...

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