Returning With A Neat Find: 1984 M635CSi

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Slownrusty
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Re: Returning With A Neat Find: 1984 M635CSi

Post by Slownrusty »

Well driving the car was short lived, I got a wild hair and decided it is time to remove the complete rear end, all suspension, brakes and structural components and give everything a big refresh!

Before pictures.
Before 1.JPG
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Before 2.JPG
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Before 3.JPG
Before 3.JPG (875.5 KiB) Viewed 4758 times
Before 4.JPG
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Slownrusty
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Re: Returning With A Neat Find: 1984 M635CSi

Post by Slownrusty »

Before 5.JPG
Before 5.JPG (1.02 MiB) Viewed 4758 times
Before 6.JPG
Before 6.JPG (956.39 KiB) Viewed 4758 times
Dog Bones Before 1.JPG
Dog Bones Before 1.JPG (876.67 KiB) Viewed 4758 times
Heat Shield Before.JPG
Heat Shield Before.JPG (886.17 KiB) Viewed 4758 times
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Slownrusty
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Re: Returning With A Neat Find: 1984 M635CSi

Post by Slownrusty »

Rear Axles Before 1.JPG
Rear Axles Before 1.JPG (970.34 KiB) Viewed 4758 times
Rear Axles Before 2.JPG
Rear Axles Before 2.JPG (1004.77 KiB) Viewed 4758 times
Rear Axles Before 3.JPG
Rear Axles Before 3.JPG (861.15 KiB) Viewed 4758 times
Rear End Before 1.JPG
Rear End Before 1.JPG (1.06 MiB) Viewed 4758 times
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Slownrusty
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Re: Returning With A Neat Find: 1984 M635CSi

Post by Slownrusty »

Rear Sway Bar End Link Before.JPG
Rear Sway Bar End Link Before.JPG (1003.33 KiB) Viewed 4758 times
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Sbeaud
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Re: Returning With A Neat Find: 1984 M635CSi

Post by Sbeaud »

Keep up the great work. Can't wait to see the finished product.

Scott
1988 M6
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Slownrusty
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Re: Returning With A Neat Find: 1984 M635CSi

Post by Slownrusty »

Sbeaud wrote: Sun Mar 13, 2022 4:31 pm Keep up the great work. Can't wait to see the finished product.

Scott
Thanks Scott!

I swear I "think" I know what I'm doing...don't try this at home kids.
Fire Rear Cross Member Bushing Removal.JPG
Fire Rear Cross Member Bushing Removal.JPG (1006.94 KiB) Viewed 4731 times
Rear Cross Member Bushing Removal.JPG
Rear Cross Member Bushing Removal.JPG (1.04 MiB) Viewed 4731 times
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86_6series
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Re: Returning With A Neat Find: 1984 M635CSi

Post by 86_6series »

Thanks
86-635CSi
96-MB C220 SOLD
98-740i
71-Continental MK3
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Sbeaud
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Re: Returning With A Neat Find: 1984 M635CSi

Post by Sbeaud »

Carbeque! Interested in your methods/materials: surface prep, paint, application.

Thanks

Scott Beaudry
1988 M6
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Slownrusty
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Re: Returning With A Neat Find: 1984 M635CSi

Post by Slownrusty »

Well the entire rear end is out, all components including braking system.

Time now for the refresh. I was able to drop off all the items to be powder coated today and then placed an order with BMW for some parts. So the next few weeks will be busy for sure!
Rear Diff Before.JPG
Rear Diff Before.JPG (1.09 MiB) Viewed 4705 times
Interestingly the right strut top had a bent stud...hmm!
Right Rear Strut Top.JPG
Right Rear Strut Top.JPG (1.29 MiB) Viewed 4705 times
Stuff to be powder coated:
Parts Before Powder Coating 4.JPG
Parts Before Powder Coating 4.JPG (1.15 MiB) Viewed 4705 times
Parts Before Powder Coating 3.JPG
Parts Before Powder Coating 3.JPG (1.27 MiB) Viewed 4705 times
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Slownrusty
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Re: Returning With A Neat Find: 1984 M635CSi

Post by Slownrusty »

Naked Chassis.
Chssis Before 3.JPG
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Chssis Before 2.JPG
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Slownrusty
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Re: Returning With A Neat Find: 1984 M635CSi

Post by Slownrusty »

I have been chipping away at the car over the past few weeks.

Here are some progress pictures. Scrubbed, scrubbed then power washed the wheels wells. I also ran a new bead of 3M seam sealer, primed and painted the wheel wells.
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DSCN2650.JPG (876.03 KiB) Viewed 4503 times
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DSCN2652.JPG (975.51 KiB) Viewed 4503 times
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Slownrusty
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Re: Returning With A Neat Find: 1984 M635CSi

Post by Slownrusty »

And Painted
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Slownrusty
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Re: Returning With A Neat Find: 1984 M635CSi

Post by Slownrusty »

Parts back from the powder coaters:
Powder Coated Parts 1.JPG
Powder Coated Parts 1.JPG (1.05 MiB) Viewed 4501 times
Right Trailing Arm Before 1.JPG
Right Trailing Arm Before 1.JPG (1005.81 KiB) Viewed 4501 times
Left Trailing Arm Before 1.JPG
Left Trailing Arm Before 1.JPG (1.14 MiB) Viewed 4501 times
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Slownrusty
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Re: Returning With A Neat Find: 1984 M635CSi

Post by Slownrusty »

Removing the trailing arm bushings were challenging! First fire to melt the rubber witht he inner metal shells and then I had to use a SawZall and then an air chisel to remove the outer shells..that was some work!
Left Trailing Arm Before 6.JPG
Left Trailing Arm Before 6.JPG (1 MiB) Viewed 4437 times
Left Trailing Arm Before 7.JPG
Left Trailing Arm Before 7.JPG (936.36 KiB) Viewed 4437 times
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Slownrusty
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Re: Returning With A Neat Find: 1984 M635CSi

Post by Slownrusty »

Managed to get a few hours squeezed in before bed tonight and start the re-assembly.
Re-Assembly 2.JPG
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Re-Assembly 1.JPG
Re-Assembly 1.JPG (863.83 KiB) Viewed 4437 times
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635sharknose
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Re: Returning With A Neat Find: 1984 M635CSi

Post by 635sharknose »

Very nice Yasin! =D>
Paul
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1987 635CSi Bronzitbeige
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Sbeaud
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Re: Returning With A Neat Find: 1984 M635CSi

Post by Sbeaud »

Yasin --

Did you attempt to press out the rear trailing arm bushings before resorting to the carbeque method? Wondering how hard they are to press out.

Car looks fantastic!

Scott
1988 M6
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Re: Returning With A Neat Find: 1984 M635CSi

Post by Slownrusty »

Thanks guys.

Scott - You need an 80-ton press to get the bushings out of the Trailing Arms...80 tons!! My puny 15-ton couldn't budge them a millimeter. A friend of mine who restores BMWs says many times they do not remove the trailing arm bushings, as they are usually in good condition and the fact they are also PITA.

Anyway, I am just about done with the rear end, brake, chassis and suspension refresh. I'm excited to drive the car.
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Sbeaud
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Re: Returning With A Neat Find: 1984 M635CSi

Post by Sbeaud »

Wow. 80 tons. I don't even have a press! Went to a friends place to use his small press to replace the front strut rod bushing, but we couldn't find anything matching the outside diameter of the bushing, so... I was at the BMW dealer getting some new self locking nuts for the ball joints and asked if they could press in the new Lemforder bushings. The parts guy was nice enough to take the control arms back and do them himself! Sometimes good things happen.

Your car looks really great. I know from experience the work required to clean the underbody. Would be nice if that dry ice cleaning process would become more affordable.

Scott
1988 M6
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Slownrusty
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Re: Returning With A Neat Find: 1984 M635CSi

Post by Slownrusty »

I said to myself that I would not touch the front end..just leave it alone...that thought lasted all of 10 minutes.

Before:
DSCN2745.JPG
DSCN2745.JPG (1.12 MiB) Viewed 4116 times
DSCN2759.JPG
DSCN2759.JPG (954.34 KiB) Viewed 4116 times
Scrubbed, Sanded & then primed:
DSCN2760.JPG
DSCN2760.JPG (853.72 KiB) Viewed 4116 times
DSCN2761.JPG
DSCN2761.JPG (928.58 KiB) Viewed 4116 times
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Slownrusty
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Re: Returning With A Neat Find: 1984 M635CSi

Post by Slownrusty »

And all the new stuff, waiting to be installed:
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DSCN2777.JPG
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Sbeaud
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Re: Returning With A Neat Find: 1984 M635CSi

Post by Sbeaud »

You are obsessed - in a good way! Car is looking great - I just did a similar job on my M6. It's at the BMW dealer now getting an alignment and some of the chassis bolts torqued that were a little too much for me to do with limited clearance (no lift...)

Wondering what the thinking is on the wheelwell wiring for the speed sensor and brake wear sensor. The sensors are working fine, but the sheathing is crumbling. I noticed that the wheel speed sensor is $290 for the front, so I'm not interested in replacement. Any sheathing suggestions from the forum?

Scott
BMW M6 Left Front Suspension.jpg
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BMW M6 Left Front Suspension.jpg
BMW M6 Left Front Suspension.jpg (402.34 KiB) Viewed 4107 times
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1988 M6
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Slownrusty
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Re: Returning With A Neat Find: 1984 M635CSi

Post by Slownrusty »

That look great Scott!
Nice work.

For the crumbled sheathing, I took some small diameter silicone hose and I cut it longitudinally and fit it over the wires.

Wrapped up the front suspension install last night...finally!
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Re: Returning With A Neat Find: 1984 M635CSi

Post by 635sharknose »

Very good work! This one will look just as great as your previous E24 when it's ready. =D>
Paul
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Slownrusty
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Re: Returning With A Neat Find: 1984 M635CSi

Post by Slownrusty »

Thanks Paul.

Yesterday was a productive day as I got the car back on its wheels (finally!)

I think the front could come down another 1/2" or so, but it should settle as I drive it.

Overall the car looks good and glad the goofy high ride height from when I bought it is now gone. Plus when I bought it last year the shocks \ struts were shot,
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