This Blog is Dormant

Until the Fjiord 2002 is on the road. I am posting updates on Bluey on the BMW2002FAQ http://www.bmw2002faq.com/topic/134019-73-fjord-with-megasquirt/

Ill be back!

Sidetracked!

I bought another 2002! Saw this car a few months ago when i bought some wheels off the owner and last week spotted it on Trade Me and took the plunge. A few photos -

Came with a heap of spares

Extra steering box and 4 servos

Megasquirt Relay box

Megasquirt ECU

The main challenge - Electrics

Controlled by toothed wheel on crank

Inside the megasquirt V3.0 board with Megasquirt 2 (I think!)

I believe origional carpets - faded but not worn

E30 seats - fit nicely and match the blue interior

The bad - floor rust - I've had plenty of practise fixing this!

New frost plug i think

Matching body and engine numbers

Fuel injection from a E30 318i

A quick check with BMW in Germany revealed 'The BMW 2002 rhd VIN 4200697 was manufactured on November 7^th, 1973 and delivered on November 14^th, 1973 to England. The original colour was Fjord metallic, paint code 037.'

The registration for this one is live so all it needs is a new WOF (Warrant of Fitness) and i can get it back on the road.

Want to get this finished by the middle of next year to use as my daily driver so every expense will be saved on cosmetics, just want to make it legal and reliable.

Meanwhile the roundie is mothballed until squarie gets back on the road. Don't have the space or energy or money to have 2 projects going at one time!

Hofmeister kink rust

There is some nasty rust in the Hofmeister kink on both sides of the car - time to investigate!

I don't think the hole is supposed to be there! Revealed when the window rubber was removed

Looks OK from inside though!

Not much left after cutting out the rust

Outer panel is repairable, its the inside area that had turned to rust

After looking at ways to repair this i realise this is probably beyond my metal forming skills to bend up the compound curves needed to do a good repair - i need to find a rust cut! As 2002s are like hens teeth in NZ i will be hitting up 2002FAQ and UK 2002 forums to hopefully get hold of a couple of rust cuts - fingers crossed.

B Pillar repair Pt2

Finished B pillar repair, treated inside of pillar with 2 coats of Brunox and cavity wax and temporary protection of outside with zinc primer

Inside U section patch welded in

And ground off

From inside

Cut out sections re welded back in

Sorry -bit slack on the photos on this repair!

B Pillar repair Pt1

The rusty base of the B Pillar needs repair, this area is where the quarter panel joins the pillar, i wanted to make repairs without removing the quarter panel which is beyond the scope of this refurbishment but needed to replace rusted through steel

Rust damage

Spot welds drilled out and sections removed to reveal extent of rust

Outer skin of pillar removed to expose rusted inner skin

Perforated rust on inner skin removed

16 gauge used to form shape

Radius looks OK

Ends left long to trim up after welding in

Shaped - the old and the new

And tacked in (note factory brazed on quarter panel)

Ive found the limit of how far I'm prepared to go! A restoration would involve unpicking whole panels and buying new to replace. I will be removing all perforated steel, sometimes leaving light surface pitted steel that i will then treat to some serious rustproofing - Brunox epoxy rust treatment and Cavity wax to areas i cant reach and mechanical rust removal and epoxy primer to those I can.

Roof repair continued

Tackled first layer of roof repair

Bent in brake to match existing contour

Shaped, drilled for plug welds and weld through primer applied

Welded in

Primed ready for next layer

Sighted down the roof line, contour as existing shape, so far so good!

Quarterpanel investigation

I decided to find out the extent of the rust damage to the quarter panel to then make a plan of attack

B Pillar rust, this will be challenging- lots of layers

Behind rear wheel arch, wire wheel revealed bog, fairly small area though

Wheel arch rust also not too bad

Flange between outer and inner inner wheel arch rust free!!

Top of wheel arch also good

Outer arch cut away to reveal inner arch, again fairly localised

Trunk floor on drivers side

Rust cut out ready for patching

Quarter panel is salvageable, decided to wait until i have built the rotisserie, which will make access to weld much easier

Drivers footwell continued

Final plates on the drivers side

Firewall plate welded in

And from the outside

Using the new toy - homemade sheet metal brake

Rough and ready but it bends 20 gauge nicely

Final floor plate formed

And shaped and drilled