Time for an overhaul of my 1.9 '98 BMW Z3 Individual

[Matt Barnes]

Afternoon all. so.. I've bitten the bullet. I think my MoT station has run out of A4 paper listing all the advisories (mainly corrosion based). Bodywork is fine ..it's just the mechanicals. So I'm going for it. Rear subframe off, drop the tank; front sub frame off, Sill covers off and do the whole lot. Ordered the following so far:
- 25ft of kunifer brake pipe, flaring kit and fittings; Anti Roll bar links; Track rod ends; Por15 Metal Prep, POR15 paint; Anti gravel paint, seam sealer; rear discs and handbrake shoes; handbrake cables; front "lollipop" bushes

Debating whether to go for Flo-Flex bushes and RTABs at the rear; upgrading the shocks and springs; replacing all the brake hoses. Hopefully I'll provide updates along the way, plus as I'll be doing this all on my tod, any advice welcome !

oh... and I'll be doing it on my driveway, with a Jack and axle stands...as my garage isn't big enough to house a car !

cheers
Matt

 

[andyglym]

That's a good effort outside Matt. Pop up a Progress Thread

 

[Althulas]

At least you have a drive wayMy Recommend tools a cheap corded angle grinder as it doesn’t matter if you knacker it out by the time you’ve finished, wire cups and abrasive discs for cleaning up the rust. I used acids as well to clean the metal. A quality impact wrench in handy to make quick work of stubborn nuts and bolts. was worth every penny, a Irvine nut grip set, there’s always one knackered nut. Have a look on Realoem of all the nuts and bolts your going to want to replace and get everything you need to keep the work flow going unless your planing to re zinc or paint your old stuff.

Have a look at mine in my sig and plenty of other builds from the zed shed to read.

 

[Matt Barnes]

cheers mate..I will..I've watched so many videos on Z3s E30s and E36s having this done, I think I know every nut and bolt in my head now...doesn't mean they'll undo though!

 

[IainP]

cheers mate..I will..I've watched so many videos on Z3s E30s and E36s having this done, I think I know every nut and bolt in my head now...doesn't mean they'll undo though!

Welcome to the “That one Neighbour” Club!

 

[Matt Barnes]

Welcome to the “That one Neighbour” Club!

View attachment 255435

hahaa...my drive will look like that...I've even got a large tarp in case it hoofs it down..having never done mechanicals of this scale before it looks quite daunting...but I'm sure it'll be fine when I get into it....he says now!

 

[Althulas]

We will be for advice. Where are you based Matt?

 

[Matt Barnes]

We will be for advice. Where are you based Matt?

cheers for that...I'm in Portchester nr Portsmouth..

 

[IainP]

hahaa...my drive will look like that...I've even got a large tarp in case it hoofs it down..having never done mechanicals of this scale before it looks quite daunting...but I'm sure it'll be fine when I get into it....he says now!

Some hooks along the front of the garage gives you this



If you have a pop up gazebo, it can end up like this when you need it

 

[Matt Barnes]

Some hooks along the front of the garage gives you this

View attachment 255449

If you have a pop up gazebo, it can end up like this when you need it

View attachment 255451

that's brilliant

 

[DrWong]

Bilt Hamber deox gel or C is amazing stuff for dissolving deeply pitted rust, but takes a long time and patience. I considered Por15 but went with two-part epoxy primer, as for every story saying Por was great there was another saying it didn't work, or that the level of prep was too costly/involved. Nobody had a bad thing to say about epoxy primer. From experience, it's very tolerant of not-perfect prep and sticks to anything. My front inner sills I did four years ago with epoxy are rock solid and I drive mine all year round, through winter etc.

For brake lines, a set of brake flare spanners could be useful, but you might end up cutting a lot of the fixings anyway given your description of the rust!

A set of small straight and angled picks would be my tool recommendation, for getting old seam sealer out of gaps and crevices etc.

Good luck with it and keep us posted!

 

[Matt Barnes]

Bilt Hamber deox gel or C is amazing stuff for dissolving deeply pitted rust, but takes a long time and patience. I considered Por15 but went with two-part epoxy primer, as for every story saying Por was great there was another saying it didn't work, or that the level of prep was too costly/involved. Nobody had a bad thing to say about epoxy primer. From experience, it's very tolerant of not-perfect prep and sticks to anything. My front inner sills I did four years ago with epoxy are rock solid and I drive mine all year round, through winter etc.

For brake lines, a set of brake flare spanners could be useful, but you might end up cutting a lot of the fixings anyway given your description of the rust!

A set of small straight and angled picks would be my tool recommendation, for getting old seam sealer out of gaps and crevices etc.

Good luck with it and keep us posted!

brilliant advice....yeah I went with POR15 as I watched Redish Motorsports on Youtube do a Z3 sills..looked very impressive...but D3SShooter used epoxy primer on his Z3M. I described to one of my workmates that the underside looked like an orange coral reef...which is pretty accurate...I'm ditching all brake lines and hoses and starting again, fuel lines need some attention and I'll get some fuel tank straps..was there a particular brand of epoxy you favoured or are they all pretty good?.. cheers

 

[Matt Barnes]

for the picks...I have "homemade ones".. thin long screwdrivers that I put in a vice and bent 90 degrees...works a treat

 

[DrWong]

I used Lechlar epoxy, it was a that or Jotun and Lechlar was meant to be better for brushing which I was planning to do/did.

I was similarly inexperienced and bought a shed load of kit before doing my sills hahaha, link to thread here: Chassis sill refresh (or lessons in optimism bias..) | BMW Z1 Z4 Z8 Z3 Forum and Technical Database - ZRoadster.org

The photos of the Bilt Hamber doing it's stuff are pretty impressive and you can also have a look at the finish from the epoxy that I used

 

[DrWong]

Other piece of advice, be very careful with any plastic hex nuts, particularly the ones holding the front wheel arch by the brake sensor connections. You can easily snap the studs they're attached if they're rusted (ask how I know etc), so safest just to cut the plastic nut away and replace.

 

[Matt Barnes]

I used Lechlar epoxy, it was a that or Jotun and Lechlar was meant to be better for brushing which I was planning to do/did.

I was similarly inexperienced and bought a shed load of kit before doing my sills hahaha, link to thread here: Chassis sill refresh (or lessons in optimism bias..) | BMW Z1 Z4 Z8 Z3 Forum and Technical Database - ZRoadster.org

The photos of the Bilt Hamber doing it's stuff are pretty impressive and you can also have a look at the finish from the epoxy that I used

brilliant....thanks mate

 

[Matt Barnes]

Other piece of advice, be very careful with any plastic hex nuts, particularly the ones holding the front wheel arch by the brake sensor connections. You can easily snap the studs they're attached if they're rusted (ask how I know etc), so safest just to cut the plastic nut away and replace.

thank you! ..when I get home from work I'm going to write out all the advice I've been given.....brilliant

 

[Matt Barnes]

brilliant....thanks mate

just had a sneaky look and yeah my sills look the same as yours...I'll upload some "before" pics

 

[Stevo7682]

Are your seats still in good condition replacement all but impossible to find .
I had looked at a couple of 1.9 fiji up here in Scotland to accompany my Dakar individual model but unfortunately both just a little too far gone ended up with an Orinoco edition
Good luck with your refresh it will be worth the effort when your done fiji a rare zed not that many around especially decent condition ones.
Stephen.

 

[Matt Barnes]

Are your seats still in good condition replacement all but impossible to find .
I had looked at a couple of 1.9 fiji up here in Scotland to accompany my Dakar individual model but unfortunately both just a little too far gone ended up with an Orinoco edition
Good luck with your refresh it will be worth the effort when your done fiji a rare zed not that many around especially decent condition ones.
Stephen.

yeah seats are good..I need to do the bush replacement and I have those but all good