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Thread: Rust Repair E21

  1. #1
    Join Date
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    81 323i, e28 S52,e39 M5,

    Rust Repair E21

    I have started repairing the rust on my 323i, Would there be any interest in documenting this for the forum?

  2. #2
    Join Date
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    Northern, California
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    1982 323i e21
    yes!
    My Website

    1982 323i

    Under the Hood:

    M20B23, Dogleg tranny, K&N Box Air Filter, Hayden 11inch Pusher Fan, redline tranny/diff fluid, Dual Exhaust,3.45 open.
    Braking/Suspension:
    Steel brake lines in front, front/rear 323i disks, Front and Rear Strut Braces, Lower Alpina(Ken) Bar, Kmac Camber/Castor Plates(Raise the front 1 inch), PolyUrethane Steering Rack Mounts, Rims = RG alloy wheel set (BBS design) silver 6x13 KBA 40324, Tires: Sumitomo 195/60/13, Struts: Bilstien HDs Springs: Stock
    Body:
    087-Graphit-metallic, Euro Bumpers, BBS Valance, Foha Rear Spoler, Yellow Hella High Beams
    Interior:
    Recaro Front Seats, Sports Steering Wheel, Kph 220 Speedometer, Vacuum gauge, Air/Fuel Gauge

  3. #3
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    Cincinnati, OH
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    323i, 530i, '13 Cooper S
    absolutely

  4. #4
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    83 320 98 318ti MSport
    i'm in...

  5. #5
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    e9 / e21 / e36
    i too support the notion...

  6. #6
    Join Date
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    '81 323i, '87 325
    always.
    e21: 1981 2.5L sleeper
    e21: 1982 323i Baur TC 1 # 4210
    e21: 1980 323i project or parts car, can't decide
    e21: track car project
    e46: 325XiT

    click here for the latest updates

  7. #7
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    '83 320i, '04 STi
    Do it! Really any type of project/DIY is worthy of a thread.

  8. #8
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    '77 320i
    Definately!

  9. #9
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    81 323i, e28 S52,e39 M5,
    Here is a shot of my B pillar rust in the window frame also a shot of the rust in the wheel well inside the car. Pics to come

    Rust in the Shock tower
    Rust in the floor
    Rust where the Fender meets the body

    Im starting this weekend on repairs so There will be lots of pics of that.
    Attached Images Attached Images

  10. #10
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    97 M3/4/5 81 E21 72 Bav
    I'm frightened about my car in the body shop.

    Good on ya, fixing all this yourself.


  11. #11
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    Quote Originally Posted by joel323 View Post
    Here is a shot of my B pillar rust in the window frame also a shot of the rust in the wheel well inside the car. Pics to come

    Rust in the Shock tower
    Rust in the floor
    Rust where the Fender meets the body

    Im starting this weekend on repairs so There will be lots of pics of that.
    Frighteningly familiar... see my resto thread.

    You ever get down to Portland much? a bunch of us are getting together tonight to help a local buddy get some work done on his Koronagelb 320i, prepping his recently emptied engine bay & freshing up a donor m10 with all new gaskets & doing some other odds & ends. look us up next time you are down here.
    e21: 1981 2.5L sleeper
    e21: 1982 323i Baur TC 1 # 4210
    e21: 1980 323i project or parts car, can't decide
    e21: track car project
    e46: 325XiT

    click here for the latest updates

  12. #12
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    Yes looking at your rust pics was very familiar. Im doing the same type of repair with cutting welding and POR15. Did you put that Headliner in yourself and where did you get it?

    I do get to Portland once a year at least

  13. #13
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    Quote Originally Posted by joel323 View Post
    Yes looking at your rust pics was very familiar. Im doing the same type of repair with cutting welding and POR15. Did you put that Headliner in yourself and where did you get it?

    I do get to Portland once a year at least
    I bought my headliner from Walloth & Nesch & yes, I installed it myself. I have TONS of pics of the install (more on that than anything else) on my photobucket site (see link in sig) & will get around to doing a complete write up some day.
    e21: 1981 2.5L sleeper
    e21: 1982 323i Baur TC 1 # 4210
    e21: 1980 323i project or parts car, can't decide
    e21: track car project
    e46: 325XiT

    click here for the latest updates

  14. #14
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    Quote Originally Posted by Jester323 View Post
    I bought my headliner from Walloth & Nesch & yes, I installed it myself. I have TONS of pics of the install (more on that than anything else) on my photobucket site (see link in sig) & will get around to doing a complete write up some day.
    I would like to see a write up , I tried to salvage the old Headliner but that lasted a few minutes into welding tha rear window frame. After looking at your resto we have very similar cars except for wheels, Do you plan to use a 2.5i top end on that super eta? I have been trying to decide on a motor for weeks, I have a 2.3 liter a 2.5i thats in the car, Or should go for an m30b35, There are drawbacks and advantages to them all. I also could do a stroker eta or super eta.

  15. #15
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    83 Hartge H23,80 323
    Super Eta's are great in that they make nice budget strokers. You don't even need a 2.5 top end, becuase the head is the same (885 casting). Drop in a chip and a 2.5I cam (and springs) and you'll pick up some good HP. Add 1.3 Motronic injection from a 2.5 and your even better off. I'm running a 2.5 with chip, headers, lightened flywheel and 17.5 lb injectors and it moves pretty well. Have a second 2.5 sitting in my garage that will become a stroker some day. I'm not a huge fan of the m30B35 becuase in my opinion they put even more weight over the front end.

  16. #16
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    My first repair to area where fender mounts, I welded in some new sheet metal, I just bought a welder last week so go easy on my skills I still have to add the jack box underneath the corner.



    This is my Drivers shock tower Its the most intimidating of the repairs.

  17. #17
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    Quote Originally Posted by joel323 View Post
    I would like to see a write up , I tried to salvage the old Headliner but that lasted a few minutes into welding tha rear window frame. After looking at your resto we have very similar cars except for wheels, Do you plan to use a 2.5i top end on that super eta? I have been trying to decide on a motor for weeks, I have a 2.3 liter a 2.5i thats in the car, Or should go for an m30b35, There are drawbacks and advantages to them all. I also could do a stroker eta or super eta.
    I'm going to run a custom cam, 2.5L intake manifold, but the head will be the same. I'm building Megasquirt so no Motronic needed for me, besides, Motronic doesn't work well with boost & I will be adding on the Eaton M90 at some point.

    The trick to the headliner is to use a good quality adhesive and lots & lots of small binder clips. Get most of the wrinkles out before you apply any adhesive, and get it all stretched into place. then, remove one section at a time and apply adhesive.
    e21: 1981 2.5L sleeper
    e21: 1982 323i Baur TC 1 # 4210
    e21: 1980 323i project or parts car, can't decide
    e21: track car project
    e46: 325XiT

    click here for the latest updates

  18. #18
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    joel, what kind of welder did you buy?
    -Josh


  19. #19
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    82 320i E21, 95 Porsche 911 Carrera, 95 MR2 NA
    Quote Originally Posted by Jester323 View Post
    I'm going to run a custom cam, 2.5L intake manifold, but the head will be the same. I'm building Megasquirt so no Motronic needed for me, besides, Motronic doesn't work well with boost & I will be adding on the Eaton M90 at some point.
    Hi Jesse,

    I don't want to highjack the thread, but I'm very interested in the Megasquirt for my M20 (2.7l with 10.5 pistons, headwork and 288 cam). How far along are you in the build? Are you using the stock 60 teeth wheel?

    Thanks,
    Marco
    Marco = 82 320i Hennarot - 95 Porsche 911 Carrera - 95 Red MR2 NA Hardtop

  20. #20
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    1979 323i BMW. 2003 GTI 20 V Turbo
    Quote Originally Posted by Marquinho View Post
    Hi Jesse,

    I don't want to highjack the thread, but I'm very interested in the Megasquirt for my M20 (2.7l with 10.5 pistons, headwork and 288 cam). How far along are you in the build? Are you using the stock 60 teeth wheel?

    Thanks,
    Marco
    Sorry for the thread hijack.
    Ditto. Same head and cam except for the fact that my car's new engine has a 2.9 liter. I am interested in Megasquirt as well or a complete stand alone.
    Last edited by jjgbmw323; 01-10-2009 at 08:41 PM.
    "..Horsepower is a measure of work done over time, or the rate at which work is done."




    http://www.cardomain.com/ride/579694/1


  21. #21
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    Hey this thread is not confined to rust I want to hear about mega squirt as well

    Quote Originally Posted by wayfast View Post
    joel, what kind of welder did you buy?

    Lincoln sp135t Mig
    Last edited by joel323; 01-11-2009 at 12:30 AM. Reason: Automerged Doublepost

  22. #22
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    well, I'm still somewhat in research/tear down mode. I've got an '88 super eta motor, so I have the lower compression, better for boost. at the present time, I'm slowly soldering up my MS main board. I still need to buy a stimulator (board that simulates engine running condition so you can test) and a relay board.

    I have also been compiling a parts list in MS Excel and quickly realized that I need to take a harder look at my budget for this, which has slowed me down. Unfortunately this morning, I realized my Excel file somehow has been corrupted. Not happy, I had some really good info in there, plus a table built on fuel injector sizing, with relation to HP & fuel pressure. I'm emailing it to my office so I can try and repair it on a newer version of the software.

    As for a 60 teeth wheel, I'm not sure I know what you mean. I am planning on running a 36-1 wheel to run my EDIS.

    My engine is currently dissassembled for the most part in order to inspect. I have a scratch in my # 5 cyl wall, I need to bring it to a machine shop to see how bad it is. IT sucks because I may need a new block in order to run the super eta pistons & my budget definately can't afford new pistons along with the added cost to have the cyl's bored.

    Mine will be a slow build as I scratch funds together a bit at a time. For now, I'm keeping the 2.3L k-jet motor running in the car.
    e21: 1981 2.5L sleeper
    e21: 1982 323i Baur TC 1 # 4210
    e21: 1980 323i project or parts car, can't decide
    e21: track car project
    e46: 325XiT

    click here for the latest updates

  23. #23
    Join Date
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    Quote Originally Posted by Jester323 View Post
    well, I'm still somewhat in research/tear down mode. I've got an '88 super eta motor, so I have the lower compression, better for boost. at the present time, I'm slowly soldering up my MS main board. I still need to buy a stimulator (board that simulates engine running condition so you can test) and a relay board.

    I have also been compiling a parts list in MS Excel and quickly realized that I need to take a harder look at my budget for this, which has slowed me down. Unfortunately this morning, I realized my Excel file somehow has been corrupted. Not happy, I had some really good info in there, plus a table built on fuel injector sizing, with relation to HP & fuel pressure. I'm emailing it to my office so I can try and repair it on a newer version of the software.

    As for a 60 teeth wheel, I'm not sure I know what you mean. I am planning on running a 36-1 wheel to run my EDIS.

    My engine is currently dissassembled for the most part in order to inspect. I have a scratch in my # 5 cyl wall, I need to bring it to a machine shop to see how bad it is. IT sucks because I may need a new block in order to run the super eta pistons & my budget definately can't afford new pistons along with the added cost to have the cyl's bored.

    Mine will be a slow build as I scratch funds together a bit at a time. For now, I'm keeping the 2.3L k-jet motor running in the car.
    Jesse, I have to do something as I have my 2.9 just about built. All it needs is this years tax returns to finish it. I have the custom Weisco pistons, s50 rods, s50 crank, plus 1 valves and ported and polished head. But I need a standalone setup or megasquirt. I would like to use a laptop to tweak it.
    "..Horsepower is a measure of work done over time, or the rate at which work is done."




    http://www.cardomain.com/ride/579694/1


  24. #24
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    You don't think you can just run motronic with a chip? Well, either way MS will be a great way to go.

    Well, I typed out a bunch, but we have hijacked this thread enough, I'm starting a new thread just for MS, let's get back to rust repair.
    e21: 1981 2.5L sleeper
    e21: 1982 323i Baur TC 1 # 4210
    e21: 1980 323i project or parts car, can't decide
    e21: track car project
    e46: 325XiT

    click here for the latest updates

  25. #25
    Join Date
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    81 323i, e28 S52,e39 M5,
    update: Finally got some progress got my genuine bmw shock tower ( not cheap)

    and removed the Rocker panel to repair the sill.

    update: Finally got some progress got my genuine bmw shock tower ( not cheap)


    and removed the Rocker panel to repair the sill.



    update: Finally got some progress got my genuine bmw shock tower ( not cheap)


    and removed the Rocker panel to repair the sill.






    Last edited by joel323; 03-11-2009 at 01:51 AM. Reason: Automerged Doublepost

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