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1981 633 CSI Revival and Refresh

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Kurtamine_
Posts: 10
Joined: Sun Nov 18, 2018 8:55 pm
Location: FL

1981 633 CSI Revival and Refresh

Post by Kurtamine_ » Tue Nov 20, 2018 2:01 am

Greetings from Florida!!

For starters I will say that I was never good at virtually documenting my builds and progress. I ask for your patience as my 8-month new (to me) purchase has inspired me to be engaged with my fellow shark tamers!

The vessel of the matter is an Arctic Blau 1981 633 CSI. I wont bore you guys with the details of how I came across it and I will just get into the details of the refresh and repairs that this beast will undergo. The vessel is rather rusty and I completely understand that most people would junk the car or part it out. I saw potential in the chassis despite the rust and I began fixing some of the rust already.
https://1drv.ms/u/s!AncWeV69IP_syjZoFvVozjCrx_RU
https://1drv.ms/u/s!AncWeV69IP_syi2-cqpKdOpHHpmE

Besides the rust the chassis needed a major suspension and brake refresh. The rear brake lines were clogged (probably with rust), the front dampeners were leaking fluid, the ball joints/tie rods were old and cracking, the bushings in the front control arms were toast, the rear subframe bushings with the RTABS were deceased, and much more to add.

My first task to tackle was the rear brakes. I changed out the brake lines with braided Condor Speed Shop brake lines, which made a tremendous difference. I also replaced the old fluid with DOT 4 brake fluid. After doing that, I still was not quite satisfied with the braking still. So, I decided to swap the rear calipers out with the E32 calipers and rotors.
https://1drv.ms/u/s!AncWeV69IP_syjh6V4y8650BZrvv
https://1drv.ms/u/s!AncWeV69IP_syj1ekbtRgIS1yOAO
https://1drv.ms/u/s!AncWeV69IP_syj9i2oCJXhoswQxY
https://1drv.ms/u/s!AncWeV69IP_syjcqlo0FOddJQfpG
https://1drv.ms/u/s!AncWeV69IP_sykJ2ZNd6k32eDNJH

As we all know E12 based suspension components do not support the e32 rear calipers and rotors. I decided to do the subframe update along with new RTABs, subframe bushings, and updated diff. This was to just satisfy the rear, for the front I decided to get new lower control arms with new bushings and ball joints, and I also found a set of used Bilstiens and H&R lowering springs from an E28. Again as most of you know, the E28 based cars never matched the E12 so I had to do some minor adjustments to make the front strut tube inserts work.

1.)I had to cut and lengthen the E12/E24 strut tubes in order for the bilsteins to thread in.
2.)The front top hat strut mounts needed a new bearing in order to fit the smaller diameter shaft size of the the E28 bilsteins, and so I went through boca bearings to get a proper sized bearing and pressed it in. (FOR REFERENCE: E28 top hat mount bolt pattern does not match the E12 based chassis)

Seperate from the suspension work that I have done so far. I have also did minor motor work such as replacing the intake boot that goes to the AFM. Which was causing a rather annoying idle surge. I also was having minor overheating problems with the motor too. So I replaced the water pump and upgraded to an electric fan and a small diameter water pump pulley. I will probably say that the smaller water pump pulley was probably the coolest modification I have done on this car to date haha.

The linked photos below are a mix of my old 1984 Alpine White E30 and my '99 mazda miata. As well as other photos of my E24.

https://1drv.ms/u/s!AncWeV69IP_sykfo1HGZY1ajktY4
https://1drv.ms/u/s!AncWeV69IP_sykGcLjbn90yBBoSb
https://1drv.ms/u/s!AncWeV69IP_sykU5ha-vCXKms9UY
https://1drv.ms/u/s!AncWeV69IP_syidYon8RDgzpxfiN
https://1drv.ms/u/s!AncWeV69IP_syiQzPQOsMzTfctKb
https://1drv.ms/u/s!AncWeV69IP_syiXzCWGsd154D0Qr
https://1drv.ms/u/s!AncWeV69IP_syivTY572Bdn-BSca
https://1drv.ms/u/s!AncWeV69IP_syi--P1_1PO0maqJZ
https://1drv.ms/u/s!AncWeV69IP_syjAH3U1TQQfIsWVY
'81 E24
'99 miata
'84 E30
'99 eclipse

Kurtamine_
Posts: 10
Joined: Sun Nov 18, 2018 8:55 pm
Location: FL

Re: 1981 633 CSI Revival and Refresh

Post by Kurtamine_ » Tue Dec 11, 2018 7:26 pm

For those of you who are interested in the mod done to the front strut housings for the late model bilsteins heres a picture.
https://1drv.ms/u/s!AncWeV69IP_szF86aRAkOal-0CrS

After fighting the drive shaft for about 2 hours I finally got rear subframe in and torqued down. I love the rear brake fitment of the e32 calipers. I have not driven it yet either but I love how different the bilsteins and the H&R springs feel. The rear is so much stiffer now, and the ride height is perfect!
https://1drv.ms/u/s!AncWeV69IP_szGU4PwPARBDEKztH
https://1drv.ms/u/s!AncWeV69IP_szGSrtewvUsqd7QDp
While I was getting ready for the maiden voyage by bleeding the new brakes. I ended up bursting the rusty brake line that goes from the master cylinder to the brass T-fitting ](*,)
https://1drv.ms/u/s!AncWeV69IP_szGHG3rMPIu_3jtsS

So now I am about to order a line from FCP Euro and then hopefully my maiden voyage can resume with the new suspension and bushings.
I pray I get it on the road solidly by the time Daytona 24hrs comes around.
'81 E24
'99 miata
'84 E30
'99 eclipse

GRNSHRK
E12 Based Guru
Posts: 2630
Joined: Thu Apr 08, 2004 3:24 pm
Location: Sunnyvale (SF Bay Area) CA

Re: 1981 633 CSI Revival and Refresh

Post by GRNSHRK » Tue Dec 11, 2018 8:50 pm

Well, that's quite some ambitious work you've taken on there =D>

Looks like you'll be dealing with some rust issues as well :cry:

Depending on the file size of your photos, you should try to show them instead of just the links, bit of a PITA :-k

Welcome and keep us posted, ready to hear about your maiden voyage \:D/
:mrgreen:
Bobbo
1980 633 CSi
Cypress Green/Pearl Beige
2011 F10 528i
2005 E46 330 Ci ZHP Cabrio
Image

You can never have too many BMW's

Kurtamine_
Posts: 10
Joined: Sun Nov 18, 2018 8:55 pm
Location: FL

Re: 1981 633 CSI Revival and Refresh

Post by Kurtamine_ » Sun Dec 16, 2018 3:07 am

Since my brake line decided to give out. I was able to drop the subframe a tad so that I have about an fist worth of space to unscrew the line from the chassis and disconnect the line from the brass T #-o

I was able to order a 10 foot straight brake line from fcp euro, and a new brass T fitting from ECS tuning. Since I have been having issues with my brake system I decided to continue the brake refresh by buying new Hawk pads for the front calipers, braided SS lines for the front calipers, and new vented front rotors. In the midst of all this I will be stripping the calipers of the aweful red spray paint that someone took upon themselves to do.

I worked a deal out at my local hydraulic shop to have them bend the 10 foot brake line. I have a bender and I would do it myself but I dont want that sort of headache especially since I am not a professional bender.
Attachments
rainy day.jpg
rainy day.jpg (35.16 KiB) Viewed 179 times
line.jpg
line.jpg (311.14 KiB) Viewed 179 times
20160105_183931794_iOS.jpg
My old E30 and Old Miata
20160105_183931794_iOS.jpg (70.29 KiB) Viewed 179 times
25.jpg
25.jpg (246.23 KiB) Viewed 179 times
'81 E24
'99 miata
'84 E30
'99 eclipse

Kurtamine_
Posts: 10
Joined: Sun Nov 18, 2018 8:55 pm
Location: FL

Re: 1981 633 CSI Revival and Refresh

Post by Kurtamine_ » Sun Dec 16, 2018 3:10 am

GRNSHRK wrote:
Tue Dec 11, 2018 8:50 pm
Well, that's quite some ambitious work you've taken on there =D>

Looks like you'll be dealing with some rust issues as well :cry:

Depending on the file size of your photos, you should try to show them instead of just the links, bit of a PITA :-k

Welcome and keep us posted, ready to hear about your maiden voyage \:D/
Thanks GRNSHRK! I appreciate the kind words.

Yes, unfortunately it is a rather rusty chassis, but I have every intention of repairing it all. I tried to do that with my old E30 but the rust was so bad even in all the structural areas that I couldnt deal with that anymore.

I plan to eventually take it to the track for light track days.

Also thanks for the tip about uploading he pictures rather then photo links!
'81 E24
'99 miata
'84 E30
'99 eclipse

Kurtamine_
Posts: 10
Joined: Sun Nov 18, 2018 8:55 pm
Location: FL

Re: 1981 633 CSI Revival and Refresh

Post by Kurtamine_ » Sun Jan 13, 2019 3:54 pm

Finally!!!!

I was able to drive the car after replacing the trunk line for the rear brakes and brass fitting. I ended up using Easy-Bend brake line as the replacement. Rest assure, FCP EURO did give me a great deal on a replacement 10ft brake line, but it would of been more tragic to bend that into place. I also replaced the front brake lines with braided SS and put in EBC brake pads 8)

I have to say all of this work was completely worth it. The brakes have never felt so amazing on this car since I have had it. Suspension wise, the car feels 1000x better, as expected since the old struts were blown.

Considering how I put in a 2.93 diff in I will say that it takes an incredible amount of time to get up to speed, as I expected. I will be swapping that out with a 3.25 LSD in the future. Also, my slim electric mishimoto fan seemed to do extremely well controlling the temps at the long red lights. I will be testing that out more thoroughly in the day time, but as of now I am please with how the car is.

Now I am a tiny bit closer to taking it to the track \:D/
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20181218_000911974_iOS.jpg
20181218_000911974_iOS.jpg (69.51 KiB) Viewed 62 times
'81 E24
'99 miata
'84 E30
'99 eclipse

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