Windscreen and Dash Removal

Screen removal was simple, the rubber was perished and needed replacing so cut through it to avoid any chance of breaking the glass trying to force it out.

Screen surround looks in excellent condition but what will the white paint hide?

Onto the dash, using yet another excellent FAQ from BMW 2002 FAQ  http://www.bmw2002faq.com/content/view/25/32/  where would i be without this forum! The dash came apart fairly easily except -

7mm bolt hiding here

and here, on either side of instrument cluster hole

These two bolts held me up, firstly locating them and then removing them, but it was a good excuse to but another tool 

1/4" drive with sockets down to 4mm

With the right socket (7mm) and extension bar the upper dash pad came off easily, lower dash pad was simple, locating the 2 screws either side of the steering column held me up for a while

But eventually it all came off

Now this is looking more like a serious project!

Factory applied black paint?

Removed all trim, wiring and foam from around the screen, a small area in the bottom left looks a little bit bent but will straighten out easily, only rust appears to be a small area on the outside rain channel, which can be repaired with a patch

Inner Fender Panel Removal

To be able to access the rust i needed to remove a section of the 'rifle butt', after a false start i have removed what i hope will be enough to get to all necessary rust repairs.

This was a mistake! Didn't think enough about what i needed to achieve to keep the repair as simple as possible, oh well nothing a few plug welds wont fix!

Cut lines marked

Cut using 1mm wheel on angle grinder

Revealed, leaving just a flat piece full of rust (right) which can be sacrificed, the idea  is to fabricate a simple flat piece to weld to the larger piece already cutout, also showing is the rusted part of inner wheel arch flange that needs surgery

So far so good

Area around sill to expose next 

Don't want to cut too much around the sill until i have welded in some support between the A and B pillars, and until then i wont make a decision on how to tackle the repair

Front Wing Removal

Time to get serious - Christmas is over, the rains coming so time to tear bits off!


Indicator off first, then 4 bolts at the back of the wing - actually there were only 2 still left attached to the wing, then 2 at the front across the top and nearly there

2 screws holding the indicator in

Factory Solder?

Melted off the solder and hacksawed through the 3 tack welds and off it came

Came off easily because it was only rust holding it on! Too badly gone to be salvageable? Walloth and Nesch sell pattern wings so will probably go that route

Underneath the wing the front column was badly rusted, the inner wing and 'Rifle Butt' look like a couple of patches will suffice. I will be following this awesome write up of the repair  http://www.2002tii-restoration.org/projects/front_column_100903.htm

Bad rusting but hinges are solid - repair patch only needed

Seam on Inner wing

Rear half of the rifle butt needs removing

This could be tricky

Mud, Bog and Rust Pile!

Time to put in the first parts order!

'Flip out' window removal

Took a break from the hood alignment mission to do some dismantling - need to fill some of the assorted boxes ive been collecting.
Again with help from this thread 


http://www.bmw2002faq.com/component/option,com_forum/Itemid,57/page,viewtopic/t,287506/highlight,remove+window+cotter+pin/


on 2002 FAQ forum i took out the rear window without drama. 

Inside the Hofmeister kink has seen better days!

Roof rust just keeps on growing

Is this factory installed sealant on top and bottom of B pillar or a rangi mod?

B Pillar appears in good condition _WIN!

A Naked Frame - Needs cosmetic surgery

Peeled back headliner but will need to take front and rear screens out to completely remove it

Hood Pt3

After a couple of evenings and advice from 2002 FAQ and 2002 UK forums i have edged closer to the goal, small changes to the front hinge bolts that attach to the hood and then the torsion bar arms are bringing things together, a couple more evenings may see a result??

15-20mm still to go

Looks OK at the front i think

RH is offset more than LH, adjustment of front hinges should help

Hood alignment Part2

After 4 hours of adjusting and re-adjusting the hood i think the problem may be the frame at the back is bent, which stops the hood from closing.

Cross member has come away from the frame in the centre of the hood

Drivers view, cross member has a downward curve in the centre - dont think this is right?

The hood panel from the top looks nice and straight, so it looks like i may have to drill out spot welds holding on the x-member, put the correct curve back in it and reattach, not sure yet how to proceed with this one, would like to get everything to fit nicely before i pull the rest of it apart so i can reference to other panels correctly when it comes together.

Hood Adjustment

As the hood is the only panel that doesnt fit well i will try to get it to fit before i dismantle too much more, thanks to this comprehensive write up


http://www.bmw2002faq.com/component/option,com_forum/Itemid,0/page,viewtopic/t,294651/sid,7760d28299790dfbbc8c9642a1d080bb/


 Took a few diagonal measurements across the engine bay and from the front end to the firewall and all seems to be square.


Removed the 3 front grills (2 side grills first to enable access to the 2 nuts holding the central grill on)

Grills off to access hood bolts

Rust at base of front end, radiator doesnt look great either

Also started scoring the soundproofing in readiness for the dry ice

Firewall rust

Thanks to this awesome How To http://www.bmw2002faq.com/content/view/73/32/ i removed the heater box with not much difficulty

This revealed the worst rust i have found (so far!) 

This is just a big hole between the bottom of the heater box and the transmission tunnel,  not visible from the engine bay because of a rubbery piece of sound insulation with the brake lines running over it

The bottom edge of the heater box hole had also been eaten away but the rest of the plenum looks in good condition, so may get away with a patch here rather than the whole firewall

It looks like i should be fixing this area first as it is hard to get at, so the front subframe/engine/gearbox may come out before the rear

Seat and Carpet Up

More removal of trim, passenger seat and rear trim panel out, peeled back carpet to reveal.......

Are the poppers for removable mats?

looks pretty good! No gaping holes in the floor or inner rocker panel, i will remove the soundproofing with dry ice in a couple of weeks so will reserve judgement until then. There is obvious rust in a couple of spots

Floor and inner rocker join at the front

All panels except the hood fit nicely and as yet no sign of any major crash repairs so still very positive about the rebuild

When all rusty areas are exposed for inspection i will arrange for the repair certifier to look her over to give his expert opinion on the work required and only then will i start any repair work, until then just more dismantling