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Thread: Bondo. Twin Turbo Project. 535i. Hate is bad.

  1. #1
    Join Date
    May 2009
    Location
    Vancouver, BC, Canada
    Posts
    453
    My Cars
    '89 535i/5 speed

    Bondo. Twin Turbo Project. 535i. Hate is bad.

    Well my last thread got destroyed by idiotic banter and was finally locked then deleted. It's been a month or so, so I figured I'd try again.

    Car is an '89 535iM in lachsilver with like a million miles on it.

    The goal is to make a really nice practical daily driver. No garage/track/dyno queen status. Quiet and smooth, working AC and everything else, lots of torque everywhere. 450-500whp is good enough at least for now.

    First step was to deal with the interior. It was waterlogged and smelled of ass/cigarettes/dog hair/dead people. Also it was dark blue and i wanted black.

    Initial Pics

    I got it with basket weaves and a horrid bra



    First thing was some wheels and bin the bra



    New Interior
    I got some black leather heated manual sport seats from a 4 door e36 M3 for a great deal off of craigslist, so that was my starting point.

    I had to weld on some brackets for these seats so the carpets came out. They have to be dried out and dyed anyways.

    Here is dyed vs not dyed:



    What I was starting with (just disgusting):





    Welded some simple brackets in for the M3 seats.




    Reassembled:


    Here is how the seats attach that the back, just a simple bracket:


    Overall:











    I still need to re-do the door panels, and get a new back seat. Should re-do the head liner but for now it's all liveable anyways.



    Next up some updates on suspension stuff...
    Last edited by Captain Bondo; 10-23-2011 at 02:09 PM.

  2. #2
    Join Date
    Mar 2010
    Location
    San Diego, CA
    Posts
    4,082
    My Cars
    93' Turbo e34, 04' Ram
    I like the seats. Looking forward to this thread

    TRM Turbo, Hybrid Audio Technologies stereo, S50 Cams, list goes on and on and on...

  3. #3
    Join Date
    Oct 2008
    Location
    Toronto, Canada
    Posts
    1,456
    My Cars
    2003 540i6 M-sport
    looking good, too bad the seats are manual and not electric.
    love the rims...I'd trade you for my Type II's :P

  4. #4
    Join Date
    Mar 2010
    Location
    Marin, CA
    Posts
    2,317
    My Cars
    1989 535i Manual
    Great start. Here's to hoping for an enjoyable thread.

  5. #5
    Join Date
    May 2011
    Location
    Orlando, Fla
    Posts
    852
    My Cars
    '95 525i Olympic Edition
    Nice work so far bro, much better than it was. Keep it up. Subscribed

  6. #6
    Join Date
    Mar 2008
    Location
    92' 532i
    Posts
    1,991
    My Cars
    Kansas City,MO
    Looking good so far.
    Quote Originally Posted by pimped525 View Post
    Heater stays on and think water pump is. Leaking also smell of fuel after caneing it about any ideas guys

  7. #7
    Join Date
    Apr 2009
    Location
    Driverseat
    Posts
    3,420
    My Cars
    e38 Msport, 2 e53 x5 4.6
    looks good. Will keep checking back to see your progress.

    Make it happen Captain
    Last edited by GIANUCCI E30; 10-23-2011 at 03:02 PM.

  8. #8
    Join Date
    Nov 2004
    Location
    Rochester, NewHampshire
    Posts
    2,779
    My Cars
    92' e30, 91'e34, 2k e38
    Your doing a GREAT job But 450-500whp for a DD!?!?!?
    91' E34 535iM, 92' E30 318iC "vert", 00' E38 750iL "highline"

  9. #9
    Join Date
    Jun 2009
    Location
    Odenton, MD
    Posts
    4,395
    My Cars
    90 535/4/5 + 93 540/5/6
    I dig those seats.

  10. #10
    Join Date
    May 2007
    Location
    Long Island
    Posts
    3,712
    My Cars
    E34 535i
    Glad to see you started another thread.

  11. #11
    Join Date
    Dec 2010
    Location
    Kansas City
    Posts
    1,622
    My Cars
    '11 528 Msport, '95 840i
    What did you dye the carpet with?


  12. #12
    Join Date
    May 2009
    Location
    Vancouver, BC, Canada
    Posts
    453
    My Cars
    '89 535i/5 speed
    Thanks guys! Sorry for the lack of engine related pics thus far. Aside from some intercooler test fitting I haven't done much yet. I've had a heck of a time getting manifold flanges, I have some being made locally now but I still have no eta on that.

    I have gotten most of the suspension done, though.

    One of the mini-projects was to for a large-case diff from a 750iL.


    Subframe and Large Case Diff


    The car came with a 3.46 open diff, I wanted LSD, and with the new found torque it will have I felt confident that a taller ratio would also be nice for it as a DD. So why not upgrade? So I got a nice condition 3.15 limited slip large case diff.

    This diff bolts right in to the E34 rear subframe. The axles bolted right up as well (I believe this may only be true for early manual cars).

    I'll have the drive shaft shortened and a flange adapter made in order to bolt up to the larger 750 pinion flange.
    Since I was doing the diff, I figured I'd do poly subframe bushings and fix anything else that needs fixing back there.

    Here's the "before pic:



    Nasty.

    Here is "after":



    I also put in new ebrake cables and new ebrake shoes and all new hardware.

    I didn't do anything with the brakes themselves as some sort of bbk will happen in the future.



    Some comparison pics of the diffs just for reference:






    Up next I will talk about the intercooler and zender front lip arrangement.
    Last edited by Captain Bondo; 09-15-2012 at 01:44 PM.

  13. #13
    Join Date
    Jan 2007
    Location
    Southern Oregon
    Posts
    2
    My Cars
    '91 Volvo 245
    Dig this. Bondo attention to detail and AR tendencies will make this one sexy car.

  14. #14
    Join Date
    Sep 2009
    Location
    Doraville, GA
    Posts
    1,263
    My Cars
    1994 525it/5
    Nice work i must say.

  15. #15
    Join Date
    Aug 2010
    Location
    Canada, Québec
    Posts
    2,508
    My Cars
    97' 328i, 01' 320i
    Wow!! That work should turn down any hate. I say you know what you are doing and you are not going with the back of your hand on this project.
    Error 404

  16. #16
    Join Date
    Feb 2010
    Location
    Wilmington DE
    Posts
    1,712
    My Cars
    95 540i, 87 325i vert
    Wow! Nice start.




















    I HATE YOU

  17. #17
    Join Date
    Dec 2010
    Location
    Kansas City
    Posts
    1,622
    My Cars
    '11 528 Msport, '95 840i
    Quote Originally Posted by e34projekt View Post
    What did you dye the carpet with?
    I'll ask twice, why not?! and are you happy with the results?


  18. #18
    Join Date
    Nov 2004
    Location
    Rochester, NewHampshire
    Posts
    2,779
    My Cars
    92' e30, 91'e34, 2k e38
    MAD props for your efforts AND detail work BINDO It;s great to see someone else pay attention and spend the time on detail such as cleaning and painting. It's ALWAYS worth it in the end. Looking forward to further progress
    91' E34 535iM, 92' E30 318iC "vert", 00' E38 750iL "highline"

  19. #19
    Join Date
    May 2009
    Location
    las vegas nevada
    Posts
    208
    My Cars
    91 535i 65 GrandPrix
    nice. Subscribed.

  20. #20
    Join Date
    Jun 2006
    Location
    Raleigh, NC
    Posts
    5,472
    My Cars
    E34, E368
    Looking great so far. It'll take some money to get to 450-500.


  21. #21
    Join Date
    Dec 2008
    Location
    Falcon, CO
    Posts
    805
    My Cars
    92 535i Touring, 02 X5
    a "now that you are in there" hint- Blue Urethane RTABs. Looking good.
    “Truth suffers from too much analysis.”

  22. #22
    Join Date
    Jun 2005
    Location
    Texas
    Posts
    20,728
    My Cars
    E21, E24, E34, E46
    Really nice work. The welds look excellent.


    Quote Originally Posted by BavariaE34 View Post
    looking good, too bad the seats are manual and not electric.
    Lol I thought everyone loved manual seats around here for the lighter weight?
    Last edited by Layne; 10-25-2011 at 10:29 AM. Reason: Automerged Doublepost

  23. #23
    Join Date
    Dec 2007
    Location
    South of Boston
    Posts
    8,235
    My Cars
    Scrap
    They weight difference in minimal

  24. #24
    Join Date
    Aug 2008
    Location
    Santa Clarita, CA
    Posts
    3,882
    My Cars
    e34x2+e28+e38-e30
    Great work. Another OCD cleaner/builder in our midst.

    The axles bolted right up as well (I believe this may only be true for early manual cars).

    I think because you are working with an m30 powered car... they have the bigger axle flanges already in place.

    I'll have the drive shaft shortened and a flange adapter made in order to bolt up to the larger 750 pinion flange.

    Better approach. Messing/swapping the front flange can be a pain.

    Have you set the rear sub-frame in the car? If not you may want to consider adding adjusters for camber/caster while it's out.


    Can't wait to see the rest.

    GL
    Last edited by LouieD; 10-25-2011 at 10:52 AM.

  25. #25
    Join Date
    Apr 2011
    Location
    Readyville, TN
    Posts
    348
    My Cars
    1995 540i/6
    Not something i say often, but that is a sexy sub-frame. Looking forward to seeing this progress.

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