M635 rocker cover restoration

Basic needs related to restoring a 6er including
Electronics, Bodywork, Welding, Painting, Engine Swap, etc
milroy
Posts: 36
Joined: Sun Apr 07, 2013 5:59 pm
Location: England, UK

M635 rocker cover restoration

Post by milroy »

Hi guys, i'm restoring my 1987 M635 with the M88 engine, the rocker cover and inlet manifold are in poor condition, does anyone know of/has used a professional company who can restore them? [-o<

I would like it done to look like new, i,e OEM standard with the matt black base colour and polished aluminium detailing which is a fairly specialist job as they will need stripping back first before correct heat resistant paint is applied and aliminium polished possibly with an application of lacquer. The parts are so rare I wouldn't want to risk a company without recommendation. I'm based in the midlands so local would be ideal.

Thanks!

(pic is off the net for reference, mine is in worse condition)
Last edited by milroy on Wed Sep 23, 2015 11:13 am, edited 1 time in total.
User avatar
dwcains
Posts: 1465
Joined: Sun Sep 14, 2014 6:01 am
Location: Lutz, FL

Post by dwcains »

I had my M30 cam cover done by a powdercoat shop here in the Tampa, FL area. I'd suggest looking for a shop in your area that provides the same services.

Image

Image

My cost was $75, including all required prep, and I can tell you my piece was in much worse condition than what you pictured, as it was a junkyard find for $10. I'd guess the cost might be almost double for your M cover, due to the extra details, but a properly done powdercoat finish will last a very long time.

http://www.allprocustoms.com/home.html
Dean
Lutz, FL

'85 635 CSi Euro #9402254
'87 Spider Veloce
'92 Spider Veloce
'08 350Z

Image
User avatar
sansouci
Platinum Member
Platinum Member
Posts: 1850
Joined: Mon Jul 08, 2013 10:52 pm
Location: Southampton NY

Post by sansouci »

I'm across the pond, but I might take a slightly different approach:
Remove it from the engine and give it a scrubbing with a bristle brush and some degreaser.
To brighten up the raised lettering, use a sanding block with 600 to 1200 wet/dry paper and some water. Going over it with clear might be difficult without masking first.
Some have stripped them with walnut shells and then did a powder coat and then before baking, removed the powder from the raised lettering.
That's all I know.
--Ken
Sansouci
84 E24 633Csi Auto, Bronzit/PearlBeige 6997510
93 E32 740il M60 Auto, Alpenweis/Ultramarine
60 528i M30 5-speed Green/Beige (crushed)
71 240Z 4-speed White/Blue (rusty & sold)
65 396 Chevelle 4-speed, Marina Blue/Black (stolen)
User avatar
dwcains
Posts: 1465
Joined: Sun Sep 14, 2014 6:01 am
Location: Lutz, FL

Post by dwcains »

It actually might clean up pretty well - I don't see any chipped paint. A sanding block with progressively finer grit should polish the raised areas nicely.
Dean
Lutz, FL

'85 635 CSi Euro #9402254
'87 Spider Veloce
'92 Spider Veloce
'08 350Z

Image
GripGreg
Posts: 2938
Joined: Wed Dec 14, 2011 3:13 am
Location: Long Beach, Ca.

Post by GripGreg »

The picture is a different motor. :wink:
Hit the apex
in Long Beach, Cal
Buster/'82Euro6 Build Date 9/81
Rosallina/'80 528i Build Date 4/80
m6dave
Posts: 376
Joined: Sun Oct 04, 2009 10:50 am
Location: New South Wales Australia

Post by m6dave »

I powder coated mine at home using the following method
1 strip all old paint off with paint stripper and a brass wire brush
2 polish the top of the lettering by rubbing it with a fine oil stone and lubricant
3 buff the lettering with with a calico wheel and bees wax
4 wash the whole thing with wax and grease remover then some good detergent
5 cover all the raised sections with hi temp masking tape
6 trim the masking tape with a stanley knife blade at the edge of the raised sections
7 use silicon plugs in all the holes
8 cover the underside completely with sheet metal and tape
9 apply the powder coat wrinkle powder and bake in the oven
10 remove tape and plugs after it cools

you could use wrinkle paint instead but it is not as durable as the powder coat
Attachments
engine small 1.jpg
engine small 1.jpg (232.65 KiB) Viewed 12952 times
milroy
Posts: 36
Joined: Sun Apr 07, 2013 5:59 pm
Location: England, UK

Post by milroy »

Thanks for your response guys some really good info and tips there, however due my 'to do' list being as long as ever I'm looking to out source this job to someone who has the skills and right products. I'm based in Bromsgrove in the UK (midlands area) so need a company local really...I don't trust royal mail enough to post these precious parts :-k

I've just taken pics of my car, as you can see they are pretty rough. I've bought a genuine set of HT leads as the current ones are off a m30 engine.
Attachments
3.jpg
3.jpg (1.56 MiB) Viewed 12913 times
1.jpg
1.jpg (1.18 MiB) Viewed 12915 times
User avatar
sansouci
Platinum Member
Platinum Member
Posts: 1850
Joined: Mon Jul 08, 2013 10:52 pm
Location: Southampton NY

Post by sansouci »

You've got a lot of cosmetics to deal with. Either a lot of time or a lot of GBPs. How are the mechanicals?

Have you looked through the UK magazines such as "Classics Monthly" etc?

I found two possibles in the back of "Classic & Sports Car" magazine
Colonnade Metal Finishers 020 8902 7722
De-Corrosion Services Ltd 019 325 64666

Not knowing UK geography that's the best I can do.
But another strategy is to call all the resto shops you can find and ask them who they use.

Good Luck
Sansouci
84 E24 633Csi Auto, Bronzit/PearlBeige 6997510
93 E32 740il M60 Auto, Alpenweis/Ultramarine
60 528i M30 5-speed Green/Beige (crushed)
71 240Z 4-speed White/Blue (rusty & sold)
65 396 Chevelle 4-speed, Marina Blue/Black (stolen)
guido
Posts: 301
Joined: Thu Mar 19, 2015 4:49 am
Location: UK

Re: M635 rocker cover restoration

Post by guido »

milroy, I have used this company before a number of times and thoroughly recommend their work (no affiliation).
For reference, I had some BMW alloy wheels powder coated by them in 2010 to an exact match of the original shade/colour. The original BMW finish has a limited lifetime being built up in layers of paint, black base then two coats of silver to create a shadowline finish. In comparison, the original finish isn't durable lasting maybe 3+ years depending on salt buildup on roads, regular waxing/cleaning etc. The powder coat finish however still looks fresh as the first day and brake dust comes off so easily in comparison, with no need for chemical cleaners etc.
I know you're looking for a powder coat/crackle black engine finish and not for an alloy wheel finish but they also offer this besides many other applications.

http://www.aerocoat.co.uk
User avatar
olympia57
Platinum Member
Platinum Member
Posts: 1389
Joined: Thu Sep 13, 2012 1:47 pm
Location: Ireland

Re: M635 rocker cover restoration

Post by olympia57 »

If the M88 cam cover is similar to the M30 version in that it has a cover plate under the breather take off inside then if you have it media blasted and PC'd I'd remove that cover and thoroughly clean out the underside , or better still remove it prior to having the work done .
I recently had an M30 cover textured coated ( thanks Ron and Rob /wattsmonkey ) and prior to fitting I thought I'd just check the underside of the cover to ensure that there was no blast material left there even though the internals of the cover were scrupulously clean.
After pushing some long cotton buds into the crevices between the cover plate and the casting Ifound there was still some dried residue trapped in the corners of the casting webs.
I removed the cover after power filing the heads off the retaining rivets and found a lot of blast residue that just would not have been able to have been removed any other way . Prior to doing this I had tried kerosene from a pressure gun and high pressure air but it was still there waiting on hot oil vapour breaking it down and carrying it into the engine.
I drilled and SS wired the cover back onto the cam cover afterwards .
Just a tip .........
1981 635 series 1
User avatar
hornhospital
Platinum Member
Platinum Member
Posts: 2929
Joined: Sun Jul 11, 2010 6:46 pm
Location: Silverhill, AL
Contact:

Re: M635 rocker cover restoration

Post by hornhospital »

Agree 100% about removing and cleaning under the baffle cover. This is what you're likely to find. Want that falling into your nice, clean engine?
Attachments
M30 valve cover.jpg
M30 valve cover.jpg (206.93 KiB) Viewed 12606 times
Ken Kanne
'84 633CSi "Sylvia"; '85 635CSi "Katja";'85 325e "Hazel Ann"; '95 M3 "Ashlyn"
User avatar
sansouci
Platinum Member
Platinum Member
Posts: 1850
Joined: Mon Jul 08, 2013 10:52 pm
Location: Southampton NY

Re: M635 rocker cover restoration

Post by sansouci »

Are you suggesting removing those covers BEFORE cleaning? What rivets/screws should be used to reattach them?
Sansouci
84 E24 633Csi Auto, Bronzit/PearlBeige 6997510
93 E32 740il M60 Auto, Alpenweis/Ultramarine
60 528i M30 5-speed Green/Beige (crushed)
71 240Z 4-speed White/Blue (rusty & sold)
65 396 Chevelle 4-speed, Marina Blue/Black (stolen)
User avatar
hornhospital
Platinum Member
Platinum Member
Posts: 2929
Joined: Sun Jul 11, 2010 6:46 pm
Location: Silverhill, AL
Contact:

Re: M635 rocker cover restoration

Post by hornhospital »

Yes, remove the cover (baffle cover) before cleaning. You'll be wasting your time otherwise. You cannot adequately clean in the baffles with the cover in place.

I used 3mm screws if I recall correctly. I carefully center-punched and drilled the rivet heads with a countersink bit until the head popped off, and the resulting countersunk spot is perfect for guiding the correct size tap drill. Be careful you don't drill too deep. Tap the holes using tap lube, clean the holes, and use stainless screws with Loctite to secure them.
Ken Kanne
'84 633CSi "Sylvia"; '85 635CSi "Katja";'85 325e "Hazel Ann"; '95 M3 "Ashlyn"
User avatar
olympia57
Platinum Member
Platinum Member
Posts: 1389
Joined: Thu Sep 13, 2012 1:47 pm
Location: Ireland

Re: M635 rocker cover restoration

Post by olympia57 »

I considered riveting or screwing it back on but was concerned about either of them dropping out and down into the engine .
After thought I drilled the plate and corresponding web / gusset on the casting and hard wired them together with stainless steel tie wire in eight places.
1981 635 series 1
User avatar
Da_Hose
Platinum Member
Platinum Member
Posts: 3236
Joined: Fri Mar 07, 2008 8:15 am
Location: Santa Ana, CA.

Re: M635 rocker cover restoration

Post by Da_Hose »

Wire on new screws would be great. Regular steel screws with red loctite would NEVER come out either.

Best way to recondition is masking off sealing edge, glass bead and then polish raised area with sandpaper as others have suggested. When done, the blasted surface will take powder or crinkle paint beautifully.

Jose
1987 M6 - My dream car
guido
Posts: 301
Joined: Thu Mar 19, 2015 4:49 am
Location: UK

Re: M635 rocker cover restoration

Post by guido »

milroy, I'm interested to know how you got on with this work, if you had it done?
guido
Posts: 301
Joined: Thu Mar 19, 2015 4:49 am
Location: UK

Re: M635 rocker cover restoration

Post by guido »

I've enjoyed reading Kos's thread very much: viewtopic.php?f=9&t=8230&hilit=in+the+family&start=75
It's prompted me to do the same and tidy up a few parts on my car, a M635, by powder coating/vapour blasting the following:
- rocker cover,
- power steering reservoir,
- airbox,
- ignition rail,
- scuttle panel cover for heater,
- inlet manifold/plenum,
- front and rear light surrounds,
- top of front screen motor,
- any other parts that I find that can be done eg brackets etc,

I'm just looking to tidy the car up cosmetically. Can anyone offer any pointers on what needs replacing at the same time as removing parts to be cleaned/painted?
For example, should I fit a new rocker cover gasket or can I reuse the one that comes off?
Can the ignition leads be removed from the rail?

Any other advice greatly appreciated - thanks.
milroy
Posts: 36
Joined: Sun Apr 07, 2013 5:59 pm
Location: England, UK

Re: M635 rocker cover restoration

Post by milroy »

Hi Guido, I havn't had the work done yet. I enquired with aerocoat.co.uk however they were only prepared to shot blast & finish the rocker cover with the correct black crackle coat for £85 - however this did not include the skim/polish of the raised logos so would come back all black =; I still need a company that will return it to me looking like OEM finish, I just havn't got time to do this one myself.

No real pointers other than new foam strip for the fan cover scuttle to prevent vibration . Also the wiper motor internal contacts should be cleaned and re-greased to prevent the issue where the wipers judder and won't park. Also, there are reproduction OEM quality stickers available that placed correctly give a good finishing touch.

Have you got any pics?
User avatar
Brucey
6 Series Guru
6 Series Guru
Posts: 10077
Joined: Fri Apr 09, 2004 7:17 am
Location: Cambridge, UK

Re: M635 rocker cover restoration

Post by Brucey »

guido wrote: I'm just looking to tidy the car up cosmetically.....
at risk of pointing out the b-obvious here but none of this stuff will make the car go better; there is a cost/risk/benefit thing going on here.
Can anyone offer any pointers on what needs replacing at the same time as removing parts to be cleaned/painted?
if you go about a 'cosmetic refurbishment' of the engine in the wrong way you could easily need quite a lot of mechanical work too. Doubtless you will need a stack of new gaskets, probably a rebuilt throttle linkage, all new gaskets....
For example, should I fit a new rocker cover gasket or can I reuse the one that comes off?
Can the ignition leads be removed from the rail?


I'm not sure why you would want to remove the leads from the rail unless they are being replaced. Normally a rocker cover gasket -if it can be re-used at all- is stuck to one part of the assembly, usually the cover itself. If you are refurbing the cover (blasting/recoating) you will lose the gasket for sure, and if you don't go about it (or TBs, plenum etc) in the right way you could lose the engine through trapped media.
Any other advice greatly appreciated - thanks.
nowt wrong with wanting a shiny car but priorities, cost/risk/benefit.... if your chain and guides haven't been done in a while, or the injectors cleaned, doing that would be a much better idea.

cheers
~~~~~~~~~~~~Brucey~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
ron
Platinum Member
Platinum Member
Posts: 4569
Joined: Sat Jul 10, 2004 11:35 am
Location: South Wales U.K.

Re: M635 rocker cover restoration

Post by ron »

milroy wrote: The parts are so rare I wouldn't want to risk a company without recommendation. I'm based in the midlands so local would be ideal.
This is local to you. Highly recommended as have had lots done there over the years.

http://www.redditchshotblasting.co.uk/coating/
They are ALWAYS rustier than you thought!!!!!!
'85 M #228
'87 M #367
'88 High line.
'10 X5
‘84 Alfasud 1.5 ti
guido
Posts: 301
Joined: Thu Mar 19, 2015 4:49 am
Location: UK

Re: M635 rocker cover restoration

Post by guido »

milroy wrote:Hi Guido, I havn't had the work done yet. I enquired with aerocoat.co.uk however they were only prepared to shot blast & finish the rocker cover with the correct black crackle coat for £85 - however this did not include the skim/polish of the raised logos so would come back all black =; I still need a company that will return it to me looking like OEM finish, I just havn't got time to do this one myself.

No real pointers other than new foam strip for the fan cover scuttle to prevent vibration . Also the wiper motor internal contacts should be cleaned and re-greased to prevent the issue where the wipers judder and won't park. Also, there are reproduction OEM quality stickers available that placed correctly give a good finishing touch.

Have you got any pics?
Milroy that's a shame to hear that Aerocoat don't offer the skim/polishing of the logo's etc - with that in mind I'll give the company that Ron has suggested below a try and see if they do.
On a different note, I'm happy to report that the car now drives like new :D All of the underneath of the car now gone through with bushes, arms, springs/dampers, bumpstops, topmounts/mounts etc replaced with new.
So I then moved onto other areas of the car, firstly replacing the head-unit that came with the car, as it was quite a flashy 90's style head-unit that didn't seem to fit with the rest of the interior, for a Becker Indi Pro. I then replaced the original Kenwood speakers as one in the front foot well was no longer working and overall the quality was a bit lacking, with these, that fit perfectly in the rear pods and front foot wells:
Fronts: http://www.caraudiocentre.co.uk/product ... -32214.htm
Rears: http://www.caraudiocentre.co.uk/product ... -33034.htm

Moving on, I stripped down the front and rear lights, top parts of the engine and a few other smaller parts requiring blasting/powder coating. You're right about the foam strip for the fan scuttle, mine has seen better days and will need replacing.
I'll see if I can get some pictures up but I've recently closed my Photobucket account and not really sure I want to reopen an account.
guido
Posts: 301
Joined: Thu Mar 19, 2015 4:49 am
Location: UK

Re: M635 rocker cover restoration

Post by guido »

Brucey wrote:
guido wrote: I'm just looking to tidy the car up cosmetically.....
at risk of pointing out the b-obvious here but none of this stuff will make the car go better; there is a cost/risk/benefit thing going on here.


- Sorry Brucey, not quite sure I follow you there - as I mentioned I'm doing this work purely for cosmetic reasons, or have i missed your point?

Brucey wrote:
guido wrote: Can anyone offer any pointers on what needs replacing at the same time as removing parts to be cleaned/painted?
if you go about a 'cosmetic refurbishment' of the engine in the wrong way you could easily need quite a lot of mechanical work too. Doubtless you will need a stack of new gaskets, probably a rebuilt throttle linkage, all new gaskets....


- Point taken and preparation made, new gaskets etc sourced. Thanks.

Brucey wrote:
guido wrote: For example, should I fit a new rocker cover gasket or can I reuse the one that comes off?
Can the ignition leads be removed from the rail?
I'm not sure why you would want to remove the leads from the rail unless they are being replaced. Normally a rocker cover gasket -if it can be re-used at all- is stuck to one part of the assembly, usually the cover itself. If you are refurbing the cover (blasting/recoating) you will lose the gasket for sure, and if you don't go about it (or TBs, plenum etc) in the right way you could lose the engine through trapped media.


- Noted, thanks.

Brucey wrote:
guido wrote: Any other advice greatly appreciated - thanks. nowt wrong with wanting a shiny car but priorities, cost/risk/benefit.... if your chain and guides haven't been done in a while, or the injectors cleaned, doing that would be a much better idea


- This work has already been carried out.

Thanks
User avatar
Brucey
6 Series Guru
6 Series Guru
Posts: 10077
Joined: Fri Apr 09, 2004 7:17 am
Location: Cambridge, UK

Re: M635 rocker cover restoration

Post by Brucey »

The risks involved with media blasting of rocker covers are not to be underestimated. The folk who do it may have only a weak appreciation of the risks and potential consequences of media entrapment.

It is worth noting that whilst the cover is off being refinished, the engine is open and all kinds of crud might get inside it, too.

Also I guess you may be on top of things well enough, but my point was (I suppose) that the reason my car will never be perfect is that the amount of time and effort I can apply is limited. That being the case it is best to pick and choose priorities; there are always plenty of jobs to do. Often I have refinished a part, but have later found that I'd have been better off doing something else instead.

cheers
~~~~~~~~~~~~Brucey~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
guido
Posts: 301
Joined: Thu Mar 19, 2015 4:49 am
Location: UK

Re: M635 rocker cover restoration

Post by guido »

I see Brucey, thanks for the clarification.
You're completely right and I agree - if not cleaned out correctly, and the blast media makes its way into the engine then the job which initially was to 'make things all nice and shiny' ends up being a rebuild and replacement job, costing much more. :shock: Point taken.

Whilst the cover's off, the internal workings have been sealed off to prevent ingress of foreign objects - imagine if a mouse decided it would make a nice home in there whilst the cover was off - oopps.

Very true, there's always plenty of jobs to do, it just depends which side of the fence you sit on, those that actively find work or those that are content with 'as is'.

Thanks
guido
Posts: 301
Joined: Thu Mar 19, 2015 4:49 am
Location: UK

Re: M635 rocker cover restoration

Post by guido »

milroy wrote:Hi Guido, I havn't had the work done yet. I enquired with aerocoat.co.uk however they were only prepared to shot blast & finish the rocker cover with the correct black crackle coat for £85 - however this did not include the skim/polish of the raised logos so would come back all black =; I still need a company that will return it to me looking like OEM finish, I just havn't got time to do this one myself.

No real pointers other than new foam strip for the fan cover scuttle to prevent vibration . Also the wiper motor internal contacts should be cleaned and re-greased to prevent the issue where the wipers judder and won't park. Also, there are reproduction OEM quality stickers available that placed correctly give a good finishing touch.

Have you got any pics?
Hi milroy, I've just spoken to Mike at Aerocoat.
Just to confirm, they're happy to take off the finished top layer (crackle black/powder coat) for the lettering on the rocker cover which shouldn't lead to deterioration as the remaining will have been keyed properly first.
Cheers.
Post Reply