1997 840 Build Thread

[toomanyparts]

Thought I would share some of my progress with you all, since I love reading about people bringing these things back to their original glory.

Picked up my car about four and half years ago. Decent shape overall. After dealing with a bunch of smaller issues and changing all the fluids, I had a few ideas.

As it started:
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Let's start with some of the bigger jobs...

- Rebuilt 5HP30 transmission valve body and 3 x fluid change with new filter and gasket

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[toomanyparts]

Sunroof and headliner rebuild:

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I used an epoxy resin after stripping in the board down of all the glue. Decided to go with a flat knit type pattern seen in newer cars.

[toomanyparts]

Rebuilt a set of Euro headlights with new gas shocks, glass, adjusters, buckets and low beam projectors. Also redid the wiring while I was in there. Kept them halogen.

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[toomanyparts]

Swapped the center console from wood to plastic, installed Martin's HVAC illumination bar, replaced cracked HVAC wheels and painted the radio and shift plate to clean things up.

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[toomanyparts]

Replaced chain tensioner, checked chain deflection and oil pump bolts and redid the lower oil pan gasket.

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[toomanyparts]

Had a friend machine an E46 wheel and used a E36 airbag to enable multifunction controls. Repainted the button surrounds and used new bottons. Swapped the CD changer in the trunk with an ibus unit from a 740.

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[toomanyparts]

Had another friend cut and weld the wiper arms to run Bosch Aero blades.

Attachment 544344

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Replaced driver's side lock (only one on later cars) and rebuilt both door handles with Hyper's excellent kit and installed new handles from ENGL.

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[Ed M]

Toomany, lots of good work there! What exactly did you do on that transmission rebuild? What parts did you replace? Is the door handle rebuild an upgrade?

[Timm]

Great work as usual!

[toomanyparts]

Toomany, lots of good work there! What exactly did you do on that transmission rebuild? What parts did you replace? Is the door handle rebuild an upgrade?

Ed,

I simply did the valve body rebuilt for the balls, orifices, springs and gaskets. This was simply preventive maintenance at 80K. The door handle is just Hyper's pivot kit (original pivot design fails) and the ENGL handles are metal instead of plastic. I noticed the handles sit much more flush and even with this done (before they would poke out a bit on one side).

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Great work as usual!

Thank you. Sorry to post all the updates in lumps, I just want to document it all and have a backup in case I need it.

[Mike in CT]

Toomany, you don't have the 5HP24 in your 97 840?

[jcs1966]

Sunroof and headliner rebuild: <img src="http://www.bimmerforums.com/forum/attachment.php?attachmentid=544321"/><img src="http://www.bimmerforums.com/forum/attachment.php?attachmentid=544322"/><img src="http://www.bimmerforums.com/forum/attachment.php?attachmentid=544323"/><img src="http://www.bimmerforums.com/forum/attachment.php?attachmentid=544324"/><img src="http://www.bimmerforums.com/forum/attachment.php?attachmentid=544325"/> I used an epoxy resin after stripping in the board down of all the glue. Decided to go with a flat knit type pattern seen in newer cars.

Where did you get the headliner material? I've wanted to go with knit material, but haven't been able to find it.

[Zohar]

Great work. Can you please share some tips on how to best paint the interior plastics like the shift plate? Some very tired looking plastic on my 94 840

[jeffbebe]

Awesome work!!

[toomanyparts]

Where did you get the headliner material? I've wanted to go with knit material, but haven't been able to find it.

Ebay of all places. Let me dig up the seller. 1/8 material. See link: http://m.ebay.com/itm/1-8-Flat-Knit-...405?nav=SEARCH

Toomany, you don't have the 5HP24 in your 97 840?

6/96 build date. I was surprised.

Great work. Can you please share some tips on how to best paint the interior plastics like the shift plate? Some very tired looking plastic on my 94 840

SEM colorcoat satin black. Used a semi gloss clear after. See link: http://m.summitracing.com/parts/SMM-15243
Any semi clear should work. Lightly sand with 600 or 800 grit and use an adhesion promoter. Few very light coats of each. Read the cans or spec sheet for timing.

[flirts12]

Great Job my friend. I look forward to seeing it. I can"t too see Her painted!

[toomanyparts]

Great work. Can you please share some tips on how to best paint the interior plastics like the shift plate? Some very tired looking plastic on my 94 840

I should mention that with the textured plastics, BMW often used what can be best described as a gummy plastidip on a lot of interior parts. I chose to eliminate this as even new parts failed rather quickly due to heat. I cleaned the shift plate with hot soap and water and let it soak. Then used a pumice and soft toothbrush to remove the remainder. Ran it in the top shelf of dishwasher and then cleaned with a grease and wax remover prior to paint. Wanted to leave original texture present, so I used a very mild sandpaper grade on it. If you mess up, there is a texture spray that SEM also sells that works great. Used it on a Rover CD43 faceplate to match the rest of the texture of the center console units.

[sleepy81]

Sunroof and headliner rebuild:
I used an epoxy resin after stripping in the board down of all the glue. Decided to go with a flat knit type pattern seen in newer cars.

Great work & looks very professional. Could you elaborate on the epoxy? Did you use that as an adhesive or to smooth the surface.
This is my next project but with Alcantara.

[Sameh 850i]

very nice, could you provide contact info to order the Hvac illumination, looks very good,thanks...

[toomanyparts]

I had to repair part of the sunroof opening on the headliner. For that I used JB Water Weld as it adheres to the board very nicely, is easy to smooth out and sand or file. Dries rock hard and won't come off if the surface was keyed nicely prior to application. The epoxy resin was used to reinforce the board and smooth out rough spots. I spent about 4 hours sanding it down after with 180 grit so everything was level.

Great work & looks very professional. Could you elaborate on the epoxy? Did you use that as an adhesive or to smooth the surface.
This is my next project but with Alcantara.

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Great Job my friend. I look forward to seeing it. I can"t too see Her painted!

Thanks Tony.

[vbimmer]

Had another friend cut and weld the wiper arms to run Bosch Aero blades.

Attachment 544344

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Replaced driver's side lock (only one on later cars) and rebuilt both door handles with Hyper's excellent kit and installed new handles from ENGL.

IMG_3545.jpg

could you please provide me a link where i can purchase these handles? Im desperately looking for the left side one, and can't find it anywhere.

[toomanyparts]

could you please provide me a link where i can purchase these handles? Im desperately looking for the left side one, and can't find it anywhere.

I actually have a spare door handle I could sell you. You will need to put your key in your existing lock and pull it out to transplant it to the new handle.

If you want the ENGL ones, they can be found here: http://www.engl-production.de/tuergriff-v12.html. Little pricey if all you want is a working handle though.

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Various trim - New inner door handles, shift knob, both front window regulators, replaced passenger side front glass, new rear deck, etc. Pretty much anything plastic that was available was bought new and replaced. Was able to pull the sill plates off and fix the attachment issues using some double sided tape:

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Here is a shot of the sunroof interior trim:

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Car originally came with a MagnaFlow setup which I hated. Found an original set of mufflers and sought out some NLA chrome tips from another member here and quite happy with the lack of noise.

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[toomanyparts]

After I dedid the cooling system, valve covers and replaced a few rubber and plastic pieces. Don't have an updated photo with the new ASC and cruise control cables which were replaced due to splitting and rust, but you get the idea. Would like to go back and roll over the raised bits on the acoustic cover in white for a stock look.
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Suspension - CSI sway bars front and rear, CSI springs all around, new front and rear mounts, CSI rear bump stops, revalved Bilstein dampers, pitman and idler arms, Wokke spherical upper and lower control arms, rear subframe bushings, trailing arms, Phoenix Motorsport bump steer plates and rear shock tower reinforcements, etc. Every bushing was replaced and where a spherical replacement was available from Wokke, I used it. Very happy with the outcome. Car is running a 3.64 LSD.

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[toomanyparts]

Finally found a set of visors out of a CSI. Black headliner project is done - no desire to rip the fabric off the new pillars to convert to black. Swapped in some black visor mounts and map lights to match.

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[toomanyparts]

Here is the car back from nearly 18 months with the painter. Happy overall, just some minor body adjustments to be made.
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