E34 Touring build

[Uber Soldat]

KPM_330 - Thank you sir. Will create separate threads for them.  :smilebounce:

rodga - RIT dye is used for the carpets and plush leather dye is used for the seats.

Sibonelo - That isn't an E28, it's an E24.

KingKalie - Tis actually grey  :smilebounce:

Wes - A little :fencelook:

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Engine bay primed:

There was a section of metal that had to be removed here as well.

And the bay is sprayed:

Unfortunately due to some previous owners being a bit heavy handed with somewhat fragile plastic things, we added some hinges to the tool kit holder thingy.

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Added some sound deadening and heat shielding:

Brake master cylinder and ABS unit installed:

Aircon compressors stuffs:

Steering box and lines:

Some front end stuff added:

Installed the front fuse box and associated wiring:

Couldn't quite decide on a colour...

Ready for a carpet:

And carpet is in...

Rear sedan door cards trimmed slightly and installed:

Heater core coolant pipes swapped out for non corroded ones and ready to install:

And in

Clutch line and other bits added:

Dashboard is in:

Sometime back we swapped in 540 audio wiring. Since connecting the battery (nothing blew up thankfully) we found that some of the speakers weren't working.

The culprit...

Swapped it out and now all speakers emit wonderful noise.

Front centre console and glovebox are in. Plugged in the battery, nothing blew up fortunately  :smilebounce:

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Some more interior pieces added:

Found out why stuff wasn't working in the rear hatch. I am not surprised. The last time the glass struts were changed...someone kinked the hose for the rear washer nozzle as well.

Sorted.

Cut up a front passenger side wiper, trimmed the rear one...and viola.

Repaired and painted the hatch tool holder thingy...whatever you call it.

Sprayed some more stuff.

Epic friends are epic. J needed some engine parts...I needed some seats. These will be dyed black eventually.

Never thought I'd see a brand new M5 rear bumper. well...yeah.

And of course you have to "test fit".

 

[rodga]

You really not wasting any time!

 

[MARHD]

Wow, that's a lot of progress, keep it up :thumbs:

 

[Shaheenem]

Awesome build!

 

[Tinuva]

This thread just keeps on getting better and better. Love the M5/540 touring porn here!

Sent from my Mi 9T using Tapatalk

 

[Rammlied]

Such an awesome build

 

[Rammlied]

I wonder if this ever got finished

 

[AKA]

All the best with the build

 

[Tinuva]

I wonder if this ever got finished

Also wonder 🤔🤔

 

[Uber Soldat]

Well, I fell off the face of the earth. Life got in the way and stuff

Anyways...lets continue.

Swapped on another bonnet. Much better condition than the first.

Put a stiffener in the rear bumper.

Rear cross member installed.

Front passenger door card in.

Front drivers door card in.

Windscreen wipers installed.

1 x dirty engine.

1 x not so dirty engine.

 

[Uber Soldat]

Replaced some seals:

Right engine mount:

Left engine mount:

Alternator power cable and knock sensors:

Waterpump:

Coolant accumulator:

Dampner:

Alternator:

Tensioners and pulleys:

Belts and power steering pump:

Redone power steering line and more stuff:

 

[Uber Soldat]

Flywheel and clutch mounted

Intake manifold installed

Tappet covers redone

Injector testing

…and installed

So close

Fun times.

Cleaned up the gearbox, replaced seals etc

Now I have something to play with…

Slave cylinder installed

Darnit…they made it too long :-(

Installed the tool holder.

 

[Uber Soldat]

An oil pan - I think it's clean enough.

ooooh...wiring

And done

They got it right the second time around...sorta

Nice and shiny

Time for a first start with the obligatory missing exhaust

Its finally on the ground. Have to do something about that wheel gap

Exhaust is back on. Far too quiet now.

And it actually drove, quite nicely. Tyres are rubbish so couldn't really tell if there was any prop shaft vibration.

Bath time

Added a plate surround and a badge

Trying out a Dynaudio wheel well subwoofer. Really impressed with the bass output

No body smuggling here...I swear. Added some throwing star covers.

Now this is going to be interesting. More on this later.

Great success.

 

[Uber Soldat]

The Touring chronicles - Part...Complicated friggen sunroof

First off, find all the broken pieces...

Have a spare sunroof cassette and strip it down

Cables and stuff

"Repaired" actuator thingy

These hold up and move the rear panel

All assembled.

Sunroof "bench testing"

Removing the current cassette

And the reason it didn't want to work

Swapped in the other cassette

And added some panels.

When plugging the motors up, they didn't want to sync (They weren't connected to the cassette at this stage). When pushing the button up (Which would presumably sync the motors) the front motor would just spin for around 20 seconds and stop. Pressing the button in any other direction, nothing would happen. The rear motor wouldn't do anything either, except a bunch of clicking relay noises from the module. Being a bit hesitant to connect the motors to the cassette itself for fear of breaking stuff, we read about the motors needing some resistance i.e grabbing onto a cable, in order to sync. We put some vice grips on the gear so it would jam against the motor housing to create said resistance when moving and the motors synced. We were then able to put the motors into their "rest" positions and bolt them onto the cassette.

I can now retire the darn tarp. Thankfully it doesn't leak.

 

[Uber Soldat]

Once the seats were plugged in, fuse 5 kept blowing. We stripped half the interior trying to find the fault, thinking it was something else. Took the seats out again and found the issue. Extra crispy wiring. Not sure how that happened.

The seats were stripped down and dyed black.

And installed.

Onto the headliner recover. Thought we'd try this ourselves.

The master upholsterer himself. I just watched.

Dyed the visors and some other bits.

Some cargo nets.

And a cargo area cover.

 

[Uber Soldat]

Was about time to sort out the ugly wheel gap. Borrowed some H&R springs on a non return basis. These come out of a M20 engined 525 sedan. They work surprisingly well in the Turd.

Have never really been happy with the look of the dyed carpets. The outer sections didn't match the center main board. Used a can of Rustoleum Fabric and vinyl dye to correct them. Once they're sprayed, the fibers tend to clump together. Let it dry and then rub the carpet with a damp cloth to get the OEM feel back.

The cargo area cover looked a bit tired. Redyed that as well.

Found some old matts in the stash and they were dyed to match.

Yet another bath...

Dyed the trim piece aorund the sunroof opening.

Not bad methinks.

Was not a huge fan of the black centers. Thought Gunmetal might look better.

 

[Uber Soldat]

Took it out to visit friends, great time for more photos:

Some photoshopped paint and wheel options:

Fixed some door seals:

Figured out why the horn wasn't working:

Stole a blind:

and cut up the spare hatch thingy for mockup:

Looks good so far:

Trimmed some metal from the spare hatch:

 

[Uber Soldat]

Added some hooks:

Then did it all again...

Looks pretty good:

E34 goodness:

 

[Uber Soldat]

Changed out the spoiler. The original was quite lumpy.

Sprayed the mirror covers with some left over paint.

Swapped out the rear springs for some H&Rs (Borrowed from a certain 525i).

Sits better.

Swapped out the wiper mechanism...again, as the one we initially put in would hardly move.

A set of these showed up.

Cut up a not-so-good spare for practice.

Did it again.

Looks pretty cool.

Found the cause of the random engine cut outs.

And..put the front bumper and skirts in primer.

 

[KPM3_30]

EPIC work - really impressive and looking forward to the finished product!