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I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

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Slownrusty
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I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by Slownrusty » Sat Nov 07, 2020 2:18 pm

I'm enjoying the road ahead on this car.



Lots of new parts ready to go in and anything metal has been powder coated, painted or Cerakoted


The interior is already finished with all new leather and headliner:
Before:
Attachments
IMG_0666.JPG
IMG_0666.JPG (733.77 KiB) Viewed 1511 times
IMG_0665.JPG
IMG_0665.JPG (777.79 KiB) Viewed 1511 times
New Parts.JPG
New Parts.JPG (1.14 MiB) Viewed 1511 times
Subframe Out 3.JPG
Subframe Out 3.JPG (1.09 MiB) Viewed 1511 times
Last edited by Slownrusty on Sat Feb 13, 2021 7:31 pm, edited 4 times in total.

Slownrusty
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Re: I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by Slownrusty » Sat Nov 14, 2020 12:46 am

When I can't sleep and I waiting for parts to arrive....I get cleaning.
Attachments
Wheel Well Before 4.JPG
Wheel Well Before 4.JPG (1.07 MiB) Viewed 1509 times
Wheel Well Before 1.JPG
Wheel Well Before 1.JPG (1.25 MiB) Viewed 1509 times
Wheel Well After 4.JPG
Wheel Well After 4.JPG (891.26 KiB) Viewed 1509 times
Wheel Well After 3.JPG
Wheel Well After 3.JPG (954.28 KiB) Viewed 1509 times
Last edited by Slownrusty on Sat Feb 13, 2021 7:32 pm, edited 1 time in total.

Jlc
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Re: I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by Jlc » Sat Nov 14, 2020 4:56 pm

How did you do the leather? Looks beautiful.
85 635CSi Bronzit

Slownrusty
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Re: I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by Slownrusty » Sun Nov 15, 2020 2:01 pm

The leather is all new panels that were cut to match the factory patterns.
It wasn't cheap.
Attachments
Rear Seats Recovered.JPG
Rear Seats Recovered.JPG (759.65 KiB) Viewed 1508 times
New Leather 3.JPG
New Leather 3.JPG (560.17 KiB) Viewed 1508 times
New Leather 1.JPG
New Leather 1.JPG (555.36 KiB) Viewed 1508 times
Last edited by Slownrusty on Sat Feb 13, 2021 7:33 pm, edited 1 time in total.

Slownrusty
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Re: I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by Slownrusty » Mon Nov 16, 2020 11:47 am

Here's a video that walks through the upcoming work:
Enjoy!
https://www.youtube.com/watch?v=sSMaj0OrkLQ&t=1s

I worked on car for 6-hours yesterday and scrubbed the chassis some more (wow...that's hard work!) and then mounted the powder coated cross-member with the new BMW mounts, pressed in the new poly-urethane bushings in the left and right rear trailing arms and installed them and also installed the new BMW diff mount. As I go through all this, every single bolt hole has their threads chased and only brand new fasteners, nuts and bolts are used.

The suspension and chassis will have ALL brand new bushings and ALL brand new fasteners.

This week I should be able to wrap up the entire rear end (install the diff, re-built axles, install all the rear brakes and the new rear Bilsteins) and will shoot another video and take some additional pictures to keep this thread current.
Enjoy.
Cheers,
Yasin
Attachments
Rear End Complete 1.JPG
Rear End Complete 1.JPG (1.04 MiB) Viewed 927 times
Rear End Complete 2.JPG
Rear End Complete 2.JPG (913.18 KiB) Viewed 927 times
Last edited by Slownrusty on Sun Mar 21, 2021 3:49 pm, edited 1 time in total.

Pasocb
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Re: I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by Pasocb » Mon Nov 16, 2020 12:49 pm

Yasin,
I really am enjoying these regular updates on your progress. It is great to see that this car is receiving some much deserved love.
Your post are an inspiration to myself and other members of our shop to better document our continuous efforts to preserve these great vehicles.
I look forward to seeing more from you about this car in the future.
Thanks,
cb
1981 635 Hennarot
1980 635 Polaris (Project)

Slownrusty
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Re: I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by Slownrusty » Tue Nov 17, 2020 1:24 pm

Pasocb wrote:
Mon Nov 16, 2020 12:49 pm
Yasin,
I really am enjoying these regular updates on your progress. It is great to see that this car is receiving some much deserved love.
Your post are an inspiration to myself and other members of our shop to better document our continuous efforts to preserve these great vehicles.
I look forward to seeing more from you about this car in the future.
Thanks,
cb
Thank-you kindly!

I'll post some updated pictures tonight. Yesterday evening I worked on the car until 9pm and made some decent progress:
1) Fitted the Differential and coupled the driveshaft

Tonight, I'll bolt-up the CV axles and hopefully tomorrow the rear brakes.

I also had new leather sewn up for the rear center arm rest.
Before:
Armrest Repair 2.jpg
Armrest Repair 2.jpg (68.92 KiB) Viewed 660 times
Armrest Repair 3.jpg
Armrest Repair 3.jpg (125.06 KiB) Viewed 660 times
After:
DSC_0059.JPG
DSC_0059.JPG (634 KiB) Viewed 659 times
Last edited by Slownrusty on Sun Apr 04, 2021 1:14 pm, edited 2 times in total.

Sbeaud
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Re: I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by Sbeaud » Tue Nov 17, 2020 3:15 pm

Wow! +1Pasocb

Really nice work and video. Very interested to see how it comes together.

Scott
1988 M6

acdakar
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Re: I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by acdakar » Tue Nov 17, 2020 7:14 pm

Impressive project... always like to see the work and detail folks put into this...
The video is good info... looking for more in the future.

PS: You need a Quick-jack... (I finally pulled the plug myself, can't believe I waited so long).

Slownrusty
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Re: I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by Slownrusty » Wed Nov 18, 2020 2:52 am

Thanks for the positive comments and thoughts - I appreciate it!

Tonight I came home late from work and it was my turn to make dinner but was able to make a little more progress:
1) Installed the rebuilt CV axles
2) Installed the e-Brake cables
In the pictures you can see all new hardware, bolts and nuts. Plus new braided stainless steel brake hoses.

Here are some pictures:



Hopefully tomorrow I have enough time to install the rear brakes and then the new Bilsteins on Thursday, with a new video!
Attachments
Rear Wheel After 2.JPG
Rear Wheel After 2.JPG (1.05 MiB) Viewed 1506 times
New Diff Mount 2.JPG
New Diff Mount 2.JPG (902.06 KiB) Viewed 1507 times
Rear End and Chassis Before 5.JPG
Rear End and Chassis Before 5.JPG (1.1 MiB) Viewed 1507 times
Last edited by Slownrusty on Sat Feb 13, 2021 7:39 pm, edited 3 times in total.

olympia57
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Re: I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by olympia57 » Wed Nov 18, 2020 10:12 am

Great progress .
Nothing nicer than re fitting fresh or new parts back on a clean prepared car .
Looking forward to seeing it coming together .
Don
1981 635 series 1

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86_6series
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Re: I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by 86_6series » Wed Nov 18, 2020 12:59 pm

Very, very nice!

Slownrusty
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Re: I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by Slownrusty » Wed Nov 18, 2020 1:51 pm

Thank you!

Here's a little trick or tid-bit of advice for you guys.

If you need to drop your diff, that's the time to change the rubber brake hose especially on the right side, with the diff in place it is a bugger to get access and tighten the metal line to the brake hose.

Cross member back from blasting and power coating with new BMW OEM bushings and all new Grade 8.8/10.9 fasteners:
Diff After 1.JPG
Diff After 1.JPG (1000.88 KiB) Viewed 1505 times
Diff has been cleaned and serviced:
Diff After 1.JPG
Diff After 1.JPG (1000.88 KiB) Viewed 1505 times
New Febi Rear Brakes Shoes fitted:
New Rear Shoes 2.JPG
New Rear Shoes 2.JPG (760.1 KiB) Viewed 1505 times
Attachments
Rear Cross Member After 1.JPG
Rear Cross Member After 1.JPG (804.6 KiB) Viewed 658 times
Last edited by Slownrusty on Sun Apr 04, 2021 1:21 pm, edited 4 times in total.

Slownrusty
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Re: I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by Slownrusty » Thu Nov 19, 2020 2:12 pm

I thoroughly cleaned and greased the e-brake mechanism where it connects to the cables and then fitted new rear e-brake shoes and rotors last night. Its humorous how much time fitting and properly adjusting the rear shoes can actually take. The e-brake now feels really good, before there was too much travel to engage it.

A summary of the work on the chassis, suspension and brakes:
1) New front (left and right) Tie Rod Assemblies (OCAP)
2) New Front Tension-Compression Rod bushings (OEM BMW)
3) New Shock bellows / dust boots front and rear (KYB)
4) New Coil Spring Pads front and rear (OEM BMW)
5) New Swaybar bushings front and rear (OEM BMW)
6) New Bilstein shocks front and rear
7) New Center Link
8) New Control arms with bushings (Moog)
9) New Brake Pads front and rear (Pagid)
10) Rebuilt calipers and cerakote
11) New Stainless Steel braided brake lines (Ireland Engineering)
12) New rotors front (slotted and x-drilled) and rear (Ireland Engineering)
13) New rear brake shoes (Febi)
14) New Differential Mount (OEM BMW)
15) New Rear Cross Member Mounts (OEM BMW)
16) New Rear trailing arm bushings - urethane (Ireland Engineering)
17) New Sway bar end links - urethane (Ireland Engineering)
18) Alignment done at SZR Pro in Houston

All brand new fasteners, nuts, bolts and washers of equal spec and grade to OEM from Belmetric
Attachments
Front Fender After 2.JPG
Front Fender After 2.JPG (902.96 KiB) Viewed 1504 times
Last edited by Slownrusty on Sun Apr 04, 2021 2:24 pm, edited 3 times in total.

Slownrusty
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Re: I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by Slownrusty » Tue Nov 24, 2020 2:25 pm

Latest Video of the rear end, suspension, subframe and diff re-installed:
https://www.youtube.com/watch?v=KvSfu8W7ifg

And pictures of the rear end, cross member, suspension and brakes re-installed:


Enjoy!
Yasin
Attachments
Reinstall the Rear End 4.JPG
Reinstall the Rear End 4.JPG (934.34 KiB) Viewed 654 times
Rear End Complete 5.JPG
Rear End Complete 5.JPG (927.49 KiB) Viewed 654 times
Rear End Complete 2.JPG
Rear End Complete 2.JPG (913.18 KiB) Viewed 654 times
Last edited by Slownrusty on Sun Apr 04, 2021 1:23 pm, edited 1 time in total.

Slownrusty
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Re: I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by Slownrusty » Thu Nov 26, 2020 2:12 am

New steering coupling installed and steering box ready to be bolted to the subframe.

Before:
Steering Shaft to Box 2.JPG
Steering Shaft to Box 2.JPG (1.15 MiB) Viewed 653 times
After:
New Steering Coupling 4.JPG
New Steering Coupling 4.JPG (907.42 KiB) Viewed 1504 times
New Steering Coupling 1.JPG
New Steering Coupling 1.JPG (740.65 KiB) Viewed 1504 times
Last edited by Slownrusty on Sun Apr 04, 2021 1:25 pm, edited 2 times in total.

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zinnocoupe
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Re: I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by zinnocoupe » Mon Nov 30, 2020 6:30 pm

Yasin, Nice work on the e24. I've watched your videos. Keep them coming. Nice to see another 944 enthusiast. I've been looking at getting one for a while. With prices rising on those its hard to find a reasonably priced one around here anyways.
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1979 Euro 635ci no longer a basketcase, just a running rust bucket!
1977 530i Partially restored and running now!
1987 635csi 60K KM Garage Queen

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Re: I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by GRNSHRK » Tue Dec 01, 2020 5:58 pm

rusty, curious about that steering coupling, think I've seen these available from Ireland Engineering :-?

Any change is road feel, smoothness, etc. :-k

Nice work BTW, you're doing a stellar job =D>
:mrgreen:
Bobbo
1980 633 CSi Cypress Green/Pearl Beige
2017 X5 M Sport Xdrive 35i Carbon Black/Ivory White
2005 330 Ci ZHP Cabrio Imola Red/Bone/Black
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Slownrusty
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Re: I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by Slownrusty » Thu Dec 03, 2020 1:35 pm

GRNSHRK wrote:
Tue Dec 01, 2020 5:58 pm
rusty, curious about that steering coupling, think I've seen these available from Ireland Engineering :-?

Any change is road feel, smoothness, etc. :-k

Nice work BTW, you're doing a stellar job =D>
Thank-you @GRNSHRK, I appreciate it.
I bought the steering coupling from Ireland Engineering, I've used these before (all be it in other cars not an E24) and they improve the steering feel and more communicative. Additionally, they last longer (more durable) than the OEM rubber ones which are prone to cracking over the years.
zinnocoupe wrote:
Mon Nov 30, 2020 6:30 pm
Yasin, Nice work on the e24. I've watched your videos. Keep them coming. Nice to see another 944 enthusiast. I've been looking at getting one for a while. With prices rising on those its hard to find a reasonably priced one around here anyways.
Thank-you kindly! I will have another video coming this weekend, as I am 100% complete on the rear end and now moved to the front end.

If you're in the market for a 944 Turbo, now is the time to get one, why not source one from the US, if you're in BC, I recommend getting one from the PNW or CA, lots of nice ones for sale. The Facebook 944 Turbo is a great place to view cars for sale. My 951 is an '87 and ownership has been great (4 years to date), you can modify them to 275-300hp and not loose an iota of reliability.

My best - Yasin

Slownrusty
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Re: I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by Slownrusty » Fri Dec 04, 2020 4:45 pm

Front subframe and front swaybar installed.

New video coming this weekend.
Attachments
Installing Front Sway Bar.JPG
Installing Front Sway Bar.JPG (809.84 KiB) Viewed 1504 times
Last edited by Slownrusty on Sat Feb 13, 2021 7:46 pm, edited 1 time in total.

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Re: I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by Slownrusty » Sat Dec 05, 2020 2:56 pm

I couldn't help myself...I went and painted the wheel wells last night...it was worth the effort and they came out great.
Attachments
New T-C Bushing 4.JPG
New T-C Bushing 4.JPG (967.69 KiB) Viewed 1503 times
New T-C Bushing 2.JPG
New T-C Bushing 2.JPG (892.25 KiB) Viewed 1503 times
Last edited by Slownrusty on Sat Feb 13, 2021 7:47 pm, edited 2 times in total.

Sbeaud
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Re: I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by Sbeaud » Sat Dec 05, 2020 6:25 pm

Very nice! Really looks sharp with the powder coating you did.
1988 M6

Sbeaud
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Re: I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by Sbeaud » Sat Dec 05, 2020 6:41 pm

You may have had the same frustration I did. Using a cleaner I couldn't get rid of some black residue - not sure what it is, but it detracts from an otherwise clean surface...
1988 BMW M6 right front wheel well - original.JPG
1988 BMW M6 right front wheel well - original.JPG (156.94 KiB) Viewed 2739 times
1988 BMW M6 right front wheel well - cleaned.JPG
1988 BMW M6 right front wheel well - cleaned.JPG (251.25 KiB) Viewed 2739 times
1988 M6

Slownrusty
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Re: I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by Slownrusty » Wed Dec 09, 2020 1:18 am

Sbeaud - lovely clean-up on your M6! Looks great under there.

I made some great progress on the front subframe, brakes and suspension in the past few days:
Front Fender After 2.JPG
Front Fender After 2.JPG (902.96 KiB) Viewed 651 times
And turning to the engine:
Intake manifold before:
Intake Manifold Before.JPG
Intake Manifold Before.JPG (975.72 KiB) Viewed 651 times
Intake Manifold Before.JPG
Intake Manifold Before.JPG (975.72 KiB) Viewed 651 times
Removed and dismantled, getting ready to clean and then powder coat:
Intake Manifold Before 3.JPG
Intake Manifold Before 3.JPG (1.26 MiB) Viewed 651 times
Last edited by Slownrusty on Sun Apr 04, 2021 1:37 pm, edited 3 times in total.

Slownrusty
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Re: I'll Be Busy For a While - 1979 Euro 635CSi (M90 Powered)

Post by Slownrusty » Sun Dec 13, 2020 3:31 pm

Latest video installment below, enjoy:

https://www.youtube.com/watch?v=qHPw7r6pxEU

Turning to the engine and a refresh:
1) New Fuel Filter (Mahle)
2) New Power Steering Belt (O Reilly)
3) New Alternator Belt (O Reilly)
4) New intake manifold gaskets (Victor Reinz)
5) New Bosch Fuel Pump
6) New Throttle Body Gasket (OEM BMW)
7) New Throttle Body to AFM Rubber Boot (OEM BMW)
8) New Thermostat
9) New Thermostat Gaskets (Victor Reinz)
10) New Engine Mounts and Transmission Mount (Ireland Engineering)
11) New Expansion tank cap (OEM Reuter)
12) New Expansion tank and level sensor (OEM BMW)
12) All new rubber hoses (O Reilly) and fuel hoses (Braided from Earls)
13) New later model AFM cover (OEM BMW)
14) New Valve cover Gasket (Ireland Engineering)
15 New NGK spark Plugs
16) New Silicone radiator hoses and coolant hoses (Ireland Engineering)
17) New 8mm Spark plug wires (Ireland Engineering)
18) New Bosch distributor cap and rotor (Ireland Engineering)
19) Oil Filter and oil Change (Bosch filter and Castrol GTX 20W50 with Redline Zinc Additive)
20) Any bolt, nut, washer removed was replaced with brand new of equal grade and spec (Belmetric)
21) Rebuilt the entire shifter assembly with brand new bushings (Ireland Engineering)
22) New Temperature Sending Unit (Ireland Engineering)
23) New Windshield Washer Bottle (OEM BMW)

Lots and lots of cleaning, scrubbing and power coating.
Engine before:
M90 Engine Before 1.JPG
M90 Engine Before 1.JPG (920.32 KiB) Viewed 649 times
Engine After:
M90 Engine Before 1.JPG
M90 Engine Before 1.JPG (920.32 KiB) Viewed 649 times
Attachments
Engine After 1.JPG
Engine After 1.JPG (971.16 KiB) Viewed 649 times
Last edited by Slownrusty on Sun Apr 04, 2021 2:00 pm, edited 1 time in total.

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