My 74 2002 project

I think its finally time to start this.
Its going to be a long project.
Maybe not project binky long (depending on money!) but 3/4 years.

My dad bought this 74 2002 in the mid 90s from his sister in laws brother.
It had been sitting in a shed on the family farm for a few years.
I actually remember playing around it as a kid !!

Anyways it seem some love around 98 but has sat (mostly in a dry garage) for 20 years.
I was handed to me last year and we did a few jobs to get it moving again.

So far its gotten new calipers on the front.New cylinders/shoes on the back brakes and 4 tyres.

First job was to make a new accelerator pedal.
Original had rusted in half :eek:

I made this pedal on the CNC machine out of billet alu.



Here as some photos of the car as she stand this evening.








Onto the areas of concern....which there is many







The rear jacking point



The boot lid



There was 4 alu plates riveted inside the boot,




Here is what they were hiding



This one was caused by a repair to the exhaust hanger below it.


And thats it for the moment.

I've picked up a few bits like a new pair of grills and a compete set of the "chrome" waist line trim(which also needs work:()
Will probably replace the 2 door skins and the bonnet.

The plan for the car.
Repair as much metal as possible and gather replacement parts.
The car needs paint,all rubber seals are shot,headliner needs replacing ,suspension refresh and rewire and an exhaust system.
Get it blasted and repair more rust then reassemble.

I will be looking for advice along the way so maybe we can learn together.

First jobs will be removing the fuel tank and repairing the boot.

kdevitt

I find shop.bmw-classic.com invaluable for parts - its the official BMW portal, shipping is free for orders over €75 (no matter how large the parts) and they're cheaper than the dealer as well. Good luck

kev1.3s

It's great to see a project start here, this forum has become more about Nct's lately.
Looks lovely and will be wonderful when done. Keep us posted.

@kev1

Thanks Kdevitt,
Thankfully the car is mostly complete,
Biggest problem I see is the snowball effect,
It was badly sprayed at some stage so that needs redoing.
To do the spray the windows need to come out but the seals are too far gone to put them back,same goes for the head liner.
So all that needs to be ready and thats without getting into the rust!

@kev1.3 thankfully it'll never see the inside of an NCT center!

Dr Turk Turkelton

kev1.3s wrote: »

It's great to see a project start here, this forum has become more about Nct's lately.
Looks lovely and will be wonderful when done. Keep us posted.

Hey kev1.3s, there is a projects and builds forum with some good projects on it.

I got a few hours today to do some more rust exploration.
I wanted to get the fuel tank out (which I did) and paint it but I filled all my containers with fuel and it still has some in it so that had to wait.
the fuel is very very clean and the tank is in good shape.
The sender for the gauge needs to be reconditioned but I haven't looked at it.

Found another aluminium patch behind the drivers side rear wheel and no surprises ....more rust!



Did some grinding back in the spare wheel well.
The massive hole at the bottom of the picture is from where some butcher welded on a towing eye!



Did a bit of poking around the rust hole I showed below the rear window.


This is kind of scary but we'll take it one patch at a time!

Also took the exhaust back box off.that thing is an absolute disaster so straight in the bin .

Im considering cutting out the wheel well completely to give more access for repairs.
Heres how she stands now

kev1.3s

You may as well take the window out, window rubber is past it anyway and theres certainly more holes in the window channel

kev1.3s

You may as well take the window out, window rubber is past it anyway and theres certainly more holes in the window channel

kev1.3s

kev1.3s wrote: »

You may as well take the window out, window rubber is past it anyway and theres certainly more holes in the window channel

Yep shes fcukered.
I'll get the boot for sorted first then I'll move onto the window .

steinbock123

I have one of these - all the 60,s & 70’s sharknoses rust like nothing on earth. The more you dig and poke, the more rust you are going to find.
You have to decide what sort of a job you actually want - a patch up or a total restoration. If you want a patch up, carry on as you are.
But if you want a proper job, you’ll have to strip the shell back to the bare bones, get it acid dipped or sandblasted and you will see exactly what’s needed, and I can tell you from looking at what you’ve already uncovered that you are going to need a lot.
It’ll be a long and expensive job.

steinbock123

steinbock123 wrote: »

But if you want a proper job, you’ll have to strip the shell back to the bare bones,

Thats the plan but I'm going to go through it bit by bit then get it dipped.
Once I get the rear done I think I'll pull out the rear suspension.

any pics of yours ?what sort of work did you do ?Got any parts?!!!:D

kev1.3s

BrownFinger wrote: »

Thats the plan but I'm going to go through it bit by bit then get it dipped.
Once I get the rear done I think I'll pull out the rear suspension.

any pics of yours ?what sort of work did you do ?Got any parts?!!!:D

As far as I know there isn't anywhere in ireland that I can dip an entire shell, unless that's changed since I did the lancia sandblasting is your only choice in ireland.

kev1.3s

kev1.3s wrote: »

As far as I know there isn't anywhere in ireland that I can dip an entire shell, unless that's changed since I did the lancia sandblasting is your only choice in ireland.

Sorry I ment get it blasted.
I don't have a trailer or even a towbar so its a bit of a pain.

Miscreant

This looks great BrownFinger, I'll definitely be following this thread as I have always loved the BMW 2002s
You might look at moving the thread in to the Projects & Builds forum (https://www.boards.ie/vbulletin/forumdisplay.php?f=1624) to make sure it doesn't get lost amongst all the other posts here.

I was changing the oil on my other car and couldn't help taking another look at the 02.
I preemptively got penetrating fluid on every bolt under the car and did a rust inspection.

Thankfully very little other than surface rust.
Can't wait to get some welding done but I need some metal.

Garzard

How's the project coming along OP? :cool:

Garzard

Garzard wrote: »

How's the project coming along OP? :cool:

Slow
I've about 5 projects on inc a total house renovation (thankfully at the end!)
I also managed to get the garage painted and the workbench set up,a massive job in itself!
rear of the car is stripped down (boot lid,lights,wiring etc)
I got some welding done on the boot floor.
It's going ok but I'm learning on the job !

I did manage to get a some new parts from a UK bmw fourm.
New rubber filler neck,a complete set of trim clips for the chrome waist line and a new drivers side wing mirror.
This car never had a passenger side mirror since I've known it.

galwaytt

kev1.3s wrote: »

As far as I know there isn't anywhere in ireland that I can dip an entire shell, unless that's changed since I did the lancia sandblasting is your only choice in ireland.

Indeed - it would have to go to the UK for dip & clean. Then back here to repair/weld etc, then back to the UK for another clean and protective dip (electrophoretic).

Jon Miller in Limerick does that, and is more than familiar with 2002's as well. http://www.classiccarworkshop.ie/restoration.html

This is the place in the UK : https://www.surfaceprocessing.co.uk/classic-vehicle-solutions/

Lovely work alright !
Would hate to see the bill !

eddhorse

Great project, best of luck with it.

Actually got something done on this!
Fuel tank stripped down to bare metal ,primed and painted.
Also stripped down the fuel level sender and thankfully it was all intack just covered in ****e.
Going to try get a few more smaller jobs done so it feels like im getting somewhere.

Another small update.
A job I had been avoiding since day one.
Removing the glue that held down the boot rubber. This **** is tough to remove.




Pics are fairly crap but back to bare metal (no rust!!) and a quick lick spray of primer to keep it fresh.



I also removed the parcel shelf/speakers.
I was expecting this to be a diaster zone but it looks really good.

kev1.3s

Looks pretty good in there alright but the proof of the pudding will be when the window comes out

I think I'll take it out soon.
I've accepted it won't be going anywhere for a few yeara.
Would have liked a few more spins but insurance is out now.

kev1.3s

kev1.3s wrote: »

Looks pretty good in there alright but the proof of the pudding will be when the window comes out

I couldnt resist it.
I've commited now.
This glass wont be going back in untill a new headliner goes in.
Headliner wont be going in untill its painted.
Paint wont be done until the body rust is gone.
An expensive spiral!



No new rust at all
Here is the extent of the known rust,the lap joint under the hinge mount needs some attention.



The frame cleaned up nicely




All clean and primed



Tempted to continue stripping but I need to start addressing the metal work.

kev1.3s

Doesn't look too bad at all. Good quality german steel.

kev1.3s

kev1.3s wrote: »

Doesn't look too bad at all. Good quality german steel.

That and it's been inside since the early 00s.
I also think the second paint job had something to do with the lack of rust.
Thick undercoat and topcoat over the original paint.

Got the car a little treat today.


Got the rear seats out .only found a tiny bit of rust and a Snickers wrapper from 1999.
Should have a few hours at it tomorrow.

Another bit of exploration done this evening.

The carpet was torn badly so that was getting replaced anyway so I just cut it around the center console.
I suspect the center console is aftermarket.

I was greeted with this lovely underlay throughout the cabin



Was expecting to have to hover up the floors but not looking too bad at all.
there is a thick layer of "dynamat" style stuff.Not sure if thats factory.
There could be rust under it but looking from the underside I don't think so.

Drivers side


Passengers side


In this (crappy and blurry pic) you can see where I picked off some of the matting.
Very clean under it.




And the one area of rust ,I think this is (or was) a bushing to the chassis leg.



Overall picture.


I hope to finish stripping the inside and the doors this week!

Took the door card off to find this



At first I thought it was masking but there is no overspray on them.
I guess a vapor barrier !

A Quinnsworth bag for life.Looking as fresh as the day it left the shop.



Here is the worst of the door rust.
Its actually much less than I though.
I know this door was replaced in the late 90s.

Behind the front wheel.




And a pic of the drivers side sill.Again replaced in the late 90s




Not too shabby at all.
I'd be quite happy if the other side was like this.

have you not seen the bargain on donedeal for 15k?:D

I got some work done on the car.
The floor of the garage got saturated during the storm on wednesday so it was hard to face going in there until it dried out.
I got the passenger door stripped and its in better shape than the drivers side.
I think it might of been reskinned as some stage.
Got a good chunk of the dynamatt stuff off and no rust under that thankfully.

I'll probably continue on stripping the dynamatt but my back is ****ed again.
After that I think I'll attack the known rust areas.

Lurching

Doesn't look too unalike my one:

very nice,
I see you removed the waist line and knee trim.
I'll be keeping the waistline trim anyway.
those seats look the part too,e21?

noelf

Lurching wrote: »

Doesn't look too unalike my one:

Apart from the rear lights .. brother-in-law wants one with the rectangular rear lights

Lurching

BrownFinger wrote: »

very nice,
I see you removed the waist line and knee trim.
I'll be keeping the waistline trim anyway.
those seats look the part too,e21?

I bought it without the waist trim, and prefer it that way personally.
They are E21 seats. The interior needs a lot of work as it's unfinished and nothing matches.

ActingDanClark

Have wanted one of these for over 40 years now !

Nekarsulm

ActingDanClark wrote: »

Have wanted one of these for over 40 years now !

Remember going to Enniskillen to look at one in TP Toppings.
Be about 1988 or 89.
You could put your fingers through the sills, it was that rusty...

ActingDanClark

I'd have to buy fully restored, my skills extend to putting petrol in

LIGHTNING

LIGHTNING wrote: »

I may have been looking at 2002's on various classic sites. Not many around (that aren't for silly money). I really should have bought one 10 years ago

Have you seen this one ?
https://www.donedeal.ie/vintagecars-for-sale/bmw-2002-project-offers-swaps/25757595?campaign=14

I'd say mine is worth about 30K

Lurching

BrownFinger wrote: »

Have you seen this one ?
https://www.donedeal.ie/vintagecars-for-sale/bmw-2002-project-offers-swaps/25757595?campaign=14

I'd say mine is worth about 30K

Now that would be a good winter project.
Would it be possible to get that on the road again with the paperwork issue?

MAJJ

LIGHTNING wrote: »

:pac: Lol yeah some of the ones I have seen lately are comical.

95 % complete !

Well its been a while,
Been chipping away at it literally.
Removing the sound deadening material and its not a fun job.

Have about 50% done now .
This section took me two hours .



I started using this locktight SF 7200 gasket remover to remove the residue and its animal stuff.



I thought I had more pictures but the drivers side front and rear are done now.
Didn't find a huge amount of rust .A hole under the pedals and a small hole on the driveshaft tunnel.





Section the right has been treated with the locktight

Chip,chip,chip

Its amazing the change a can of primer can make.



Still so much dynamatt to come off

kdevitt

Thats great progress. Is it factory sound deadening or is it actually dynamat? I've started dailying my own E30 project recently - its a great way to discover all the additional work your car actually needs.

kdevitt

kdevitt wrote: »

Thats great progress. Is it factory sound deadening or is it actually dynamat? I've started dailying my own E30 project recently - its a great way to discover all the additional work your car actually needs.

Its the factory stuff.
Thankfully I haven't found too much extra work.......yet!

Still finding the odd hour or two to go out the car.
its much easier to sit down and watch other people restore cars on youtube!

I need to get all this ****e off the inside before I can move on .

The section at over the driveshaft tunnel took around 1.5 hours to chip off.


Then there is the remains of the glue to deal with.


But it cleans up nicely and a light coat of primer later.



Found 3/4 small holes in that floor area,
Should be a much nicer place to work once its cleaned up and primed.
Then I'll get onto the fun (and expensive) parts.

Bit more done.
Floor pans are quite good thankfully.






The worst of the floor.

Drivers side floor cleaned and painted up.
Center console out and wiring cleaned up.







Not much (if any) of that wiring is original. I cant wait to make a new one.
Theres a Slovakian chap on Instagram restoring one almost the same (a tii) and he made this beauty.
https://www.instagram.com/bimmer02ti/?hl=en



Also got these casters that should help with my access.

Lurching

BrownFinger wrote: »

Not much (if any) of that wiring is original. I cant wait to make a new one.
Theres a Slovakian chap on Instagram restoring one almost the same (a tii) and he made this beauty.

Not sure I'd trust his wiring. Not even connected to the battery and it's smoking already!

Nice progress. I could do with a new centre console in mine too.
I think there have been three different generations of the dashboard over the life of the 2002. Mine is different to yours.

Wow its been a while since I posted.....
Project has progressed somewhat,lost the last 3 months to a bathroom renovation.

Around christmas I got the dash & windscreen out and the last of the sound deadening material.
As you can see under the dash is like new. One small hole on windscreen frame that was hidden with fillers.
Im a bit further on than these pics show.




Today I had the time to drop and clean the rear subframe.






Its in great shape for a 47 year old.

The subfame will be a mini project in itself over the next few months.
Strip it back completely, clean/paint and reassemble.
The price of bushings is making me cry 400e for 12 bushes to do the rear:eek:.

I'll have to disassemble the CVs and grease them.
Might do the seals on the diff, that scares me a little........

Gremlinertia

Delighted to see an update, subframe came up well with just a wash, hard to believe it's age.