tag:blogger.com,1999:blog-58311327880999738322024-03-04T22:57:52.942-10:00The E9 Eating Rust ProjectA diary occasionally dealing with the restoration of a 1973 BMW E9 coupe. This is the car generally considered to be the most beautiful BMW, with the possible exception of the 507.Gary Dunnhttp://www.blogger.com/profile/05413344583490216720noreply@blogger.comBlogger222125tag:blogger.com,1999:blog-5831132788099973832.post-65620217193064439782019-10-11T07:01:00.002-10:002019-10-11T07:01:34.937-10:00Just a brief note that I am not continuing this blog. I never did finish the E9, gave some bits away and junked the rest. I sold the Lotus to a terrific guy who I hope will finish it up.Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0tag:blogger.com,1999:blog-5831132788099973832.post-9189555865033246482014-01-12T11:21:00.000-10:002014-02-04T11:22:21.881-10:00Engine almost togetherPainting the block took longer than I thought it would, but it is done. The head is on. Last week I stayed home nursing a cold. Today I installed the new camshaft sprockets.<br />
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There is a trick to installing the timing chain not mentioned in the workshop manual.<br />
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<ul>
<li>Start by removing the tensioner completely from the front cover. Be sure to remove the spring so it doesn't fall on the ground when you have your back turned. </li>
<li>Install the sprockets just enough to turn the cams. </li>
<li>Ensure the crank is nowhere near TDC and rotate cams until timing marks are slightly below front cover. </li>
<li>Remove sprockets. </li>
<li>While ensuring the chain does not foul on anything, rotate crank (same direction it goes in) to roughly 30 deg before TDC. </li>
<li>Ensure chain is not engaged on crankshaft sprocket.</li>
<li>Install exhaust sprocket. Snug bolt but do not tighten.</li>
<li>Rotate crankshaft to TDC and engage chain at crankshaft, check alignment of exhaust sprocket.</li>
<li>Install intake sprocket.</li>
<li>Install tensioner, adjust for 0.5 in. drop of chain between sprockets.</li>
<li>Rotate crankshaft a couple of turns and come up slowly to TCD. Ensure sprocket marks line <u>up</u> with top edge of front cover.</li>
<li>Torque sprocket bolts to 26 ft. lbs.</li>
</ul>
Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0tag:blogger.com,1999:blog-5831132788099973832.post-38867002128242931572014-01-05T11:19:00.000-10:002014-02-04T11:20:35.043-10:00Finding Time to Paint The holidays have been frantic but I have managed to spend some time at the shop. As of today I have everything I took off painted with POR-15 except the block. <br />
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While eating lunch I spotted the clutch cable bracket laying on the floor. That will need the treatment even though it is not coming off. Really should do the shift linkage, too.<br />
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Another must do with engine out -- replace the coolant pipes. Where did I put them?Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0tag:blogger.com,1999:blog-5831132788099973832.post-70846920622700479972013-12-20T17:34:00.001-10:002013-12-23T12:58:50.151-10:00Paint, oil pan, cam cover, motor mounts Another good day with the Lotus. <br />
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Striped the motor mounts and cam cover. Shot the oil pan with POR-15 etching primer. Shot the cam cover with wrinkle paint. Brushed POR-15 gray on oil pan, black on motor mounts.<br />
Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0tag:blogger.com,1999:blog-5831132788099973832.post-54351817720767583922013-12-01T19:19:00.001-10:002013-12-01T19:21:33.319-10:00Sunday update with rain <p>This is the time of year when my job allows me to take a day or two off every week. Sometimes even three. These good times end in January but till then I should have more than enough time to finish the Lotus.</p>
<p>Work today was impacted by rain. Lots of it. I picked up a 3/8 in. brass pipe thread plug needed to plug an extra heater hose connection on the new front cover. Decided not to put in all the plugs until after I paint the front cover. Should look more "factory" that way. Stripped the cam cover, had to work at the door opening and dodge the raindrops.</p>
<p>Next opportunity to work is Wednesday and by then then weather should be back to normal.</p>
Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0tag:blogger.com,1999:blog-5831132788099973832.post-79007964697886905502013-11-29T17:23:00.002-10:002013-11-29T17:27:17.157-10:00Lotus gets a fancy water pumpI know it has been a few months since I posted anything. I have been working on cars, it is just that at the same time I have been working out more with the goal of doing my first triathlon. By the time I even think about writing I am too tired to start. As it turns out, swimming correctly as is required for triathlon is a lot harder to master than I thought, so I never did make one this year. After the Honolulu Century Ride in September I turned all my attention to preparing for the Honolulu Marathon on December 8th. Did the whole marathon prep race series, including to HMSA 30K, but after that I discovered I had a hernia. Just got it fixed on the 18th, and after a month not working on cars I was back at the shop today and felt great.<br />
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On August 1st I decided the time had come to push out the E9 and bring in the Lotus Europa for it's new water pump. I bought the cartridge type from Dave Ban Engineering. So, yeah, this time the head and oil pan have to come off, but not next time.<br />
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So far I have pulled the engine and transaxle, stripped the paint off the block, pulled the head, dropped the pan, replaced the front cover with the new modified version, and just today got the head back on.<br />
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<a href="http://www.flickr.com/photos/garydunn808/9439481873/" title="Lotus130801-01 by garydunn808, on Flickr"><img alt="Lotus130801-01" height="67" src="http://farm8.staticflickr.com/7291/9439481873_9ca593f68c_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/9442261390/" title="Lotus130801-03 by garydunn808, on Flickr"><img alt="Lotus130801-03" height="67" src="http://farm4.staticflickr.com/3793/9442261390_b474d06616_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/9439473833/" title="Lotus130801-04 by garydunn808, on Flickr"><img alt="Lotus130801-04" height="67" src="http://farm4.staticflickr.com/3744/9439473833_3b4326dce9_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/9439468565/" title="Lotus130801-06 by garydunn808, on Flickr"><img alt="Lotus130801-06" height="67" src="http://farm4.staticflickr.com/3777/9439468565_a777843d84_t.jpg" width="100" /></a>
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Now that it is set up, time to take stuff apart.
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<a href="http://www.flickr.com/photos/garydunn808/9439540717/" title="Lotus130802-01 by garydunn808, on Flickr"><img alt="Lotus130802-01" height="67" src="http://farm6.staticflickr.com/5336/9439540717_1b92f1e6b2_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/9439532447/" title="Lotus130802-04 by garydunn808, on Flickr"><img alt="Lotus130802-04" height="67" src="http://farm3.staticflickr.com/2892/9439532447_7f94f433fb_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/9439529917/" title="Lotus130802-05 by garydunn808, on Flickr"><img alt="Lotus130802-05" height="67" src="http://farm8.staticflickr.com/7381/9439529917_d518ca2c82_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/9442312132/" title="Lotus130802-06 by garydunn808, on Flickr"><img alt="Lotus130802-06" height="67" src="http://farm4.staticflickr.com/3805/9442312132_77cda7cc45_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/9442309438/" title="Lotus130802-07 by garydunn808, on Flickr"><img alt="Lotus130802-07" height="67" src="http://farm8.staticflickr.com/7300/9442309438_1e0b0108af_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/9442304118/" title="Lotus130802-09 by garydunn808, on Flickr"><img alt="Lotus130802-09" height="67" src="http://farm4.staticflickr.com/3765/9442304118_fe334cebcf_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/9439516837/" title="Lotus130802-10 by garydunn808, on Flickr"><img alt="Lotus130802-10" height="67" src="http://farm4.staticflickr.com/3826/9439516837_d0ccf0786f_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/9442295788/" title="Lotus130802-12 by garydunn808, on Flickr"><img alt="Lotus130802-12" height="67" src="http://farm3.staticflickr.com/2886/9442295788_0ac4c3751f_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/9439508735/" title="Lotus130802-13 by garydunn808, on Flickr"><img alt="Lotus130802-13" height="67" src="http://farm4.staticflickr.com/3733/9439508735_606afd1f92_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/9442984512/" title="Lotus130804-02 by garydunn808, on Flickr"><img alt="Lotus130804-02" height="67" src="http://farm8.staticflickr.com/7380/9442984512_86066abb69_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/9442979556/" title="Lotus130804-04 by garydunn808, on Flickr"><img alt="Lotus130804-04" height="67" src="http://farm8.staticflickr.com/7394/9442979556_accd318c15_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/9442976938/" title="Lotus130804-05 by garydunn808, on Flickr"><img alt="Lotus130804-05" height="67" src="http://farm4.staticflickr.com/3821/9442976938_63c98e5234_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/9440189311/" title="Lotus130804-06 by garydunn808, on Flickr"><img alt="Lotus130804-06" height="67" src="http://farm4.staticflickr.com/3695/9440189311_f401bb48a7_t.jpg" width="100" /></a><br />
<a href="http://www.flickr.com/photos/garydunn808/9440186707/" title="Lotus130804-07 by garydunn808, on Flickr"><img alt="Lotus130804-07" height="67" src="http://farm4.staticflickr.com/3773/9440186707_b35f3331b6_t.jpg" width="100" /></a> <a href="http://www.flickr.com/photos/garydunn808/9442969098/" title="Lotus130804-08 by garydunn808, on Flickr"><img alt="Lotus130804-08" height="67" src="http://farm4.staticflickr.com/3807/9442969098_c69f5c5160_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/9440181493/" title="Lotus130804-09 by garydunn808, on Flickr"><img alt="Lotus130804-09" height="67" src="http://farm3.staticflickr.com/2876/9440181493_7b645a368b_t.jpg" width="100" /></a><br />
Guess I didn't take any pics of the paint stripping, good thing because hard to get hands clean and dry. Took multiple coats and a lot of scrubbing to get the old enamle off. I painted this motor back in the late 70's when I had the valves redone.<br />
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These are from today. Finished with head on but rushing to get out the door. I'll try t start tomorrow with a shot of the head back on.<br />
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<a href="http://www.flickr.com/photos/garydunn808/11125676034/" title="Lotus131129-01 by garydunn808, on Flickr"><img alt="Lotus131129-01" height="67" src="http://farm8.staticflickr.com/7358/11125676034_6e24dce33d_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/11125629726/" title="Lotus131129-02 by garydunn808, on Flickr"><img alt="Lotus131129-02" height="67" src="http://farm6.staticflickr.com/5501/11125629726_f00dbd3826_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/11125662904/" title="Lotus131129-03 by garydunn808, on Flickr"><img alt="Lotus131129-03" height="67" src="http://farm8.staticflickr.com/7402/11125662904_f6373dd48d_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/11125766023/" title="Lotus131129-04 by garydunn808, on Flickr"><img alt="Lotus131129-04" height="67" src="http://farm6.staticflickr.com/5496/11125766023_55bb4cdc3d_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/11125608926/" title="Lotus131129-05 by garydunn808, on Flickr"><img alt="Lotus131129-05" height="67" src="http://farm4.staticflickr.com/3830/11125608926_381648a62f_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/11125579685/" title="Lotus131129-06 by garydunn808, on Flickr"><img alt="Lotus131129-06" height="67" src="http://farm4.staticflickr.com/3684/11125579685_acbcaec13c_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/11125636274/" title="Lotus131129-07 by garydunn808, on Flickr"><img alt="Lotus131129-07" height="67" src="http://farm3.staticflickr.com/2838/11125636274_1a663f6698_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/11125739483/" title="Lotus131129-08 by garydunn808, on Flickr"><img alt="Lotus131129-08" height="67" src="http://farm6.staticflickr.com/5496/11125739483_e32e349afe_t.jpg" width="100" /></a>
Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0tag:blogger.com,1999:blog-5831132788099973832.post-48054986864441125092013-06-23T22:05:00.000-10:002013-06-24T22:06:11.657-10:00RH door skin repaintI knew the process of attaching the door skin would bang up the paint, and that I would have to repaint the outside just to keep it from rusting while the rest of the restoration work is done. Last Sunday being Fathers Day I opted to hang out at home, so this week was my first opportunity to do the job.<br />
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Simple, really, just time consuming. Sand off the thin protective coat applied at the factory, then shoot with etching primer followed by rattle can enamel. The primer is quality stuff, but the enamel will have to come off before the real paint is laid down.<br />
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As it turned out it was a lousy, rainy day, so I only shot two coats of primer. Next week I'll finish it up.<br />
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While sanding I used some Vice-Grips to tighten up a few places were I had run out of strength last time.<br />
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<a href="http://www.flickr.com/photos/garydunn808/9131169237/" title="BMW130623-01 by garydunn808, on Flickr"><img alt="BMW130623-01" height="67" src="http://farm6.staticflickr.com/5541/9131169237_315006e4e2_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/9131209203/" title="BMW130623-03 by garydunn808, on Flickr"><img alt="BMW130623-03" height="67" src="http://farm3.staticflickr.com/2848/9131209203_468274a29b_t.jpg" width="100" /></a>
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Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0tag:blogger.com,1999:blog-5831132788099973832.post-70131103370248944342013-06-09T21:41:00.000-10:002013-06-24T21:54:25.018-10:00RH door skin attachedThis was a day I thought would never come. The door frame was ready, and the door skin was ready. The time had come to do the deed. I was more than a little apprehensive, because I knew that this was a job I had to get right the first time. Having never done it before, I had zero wiggle room.<br />
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As the pics show, I used a variety of Vise-Grips to hold the door skin in place, and several sizes of channel lock pliers to bend the flange around the edge of the frame.<br />
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The trick is to get it started, then to take a very small bite with each squeeze and gradually work the flange along. The only problem I ran into was muscle fatigue and blisters. Even though I wore gloves I had blisters for a week.<br />
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Well, there was another problem, but this one seems unavoidable. All along the edge the nice, pristine skin the pliers left a small line of disruption. Mostly looks like a narrow, shallow dent. No doubt a factory installer could avoid this, but for my first attempt I think this went very well.<br />
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<a href="http://www.flickr.com/photos/garydunn808/9131084463/" title="BMW130609-01 by garydunn808, on Flickr"><img alt="BMW130609-01" height="67" src="http://farm8.staticflickr.com/7422/9131084463_74e9688dd5_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/9131194749/" title="BMW130609-11 by garydunn808, on Flickr"><img alt="BMW130609-11" height="67" src="http://farm3.staticflickr.com/2810/9131194749_b10a945db1_t.jpg" width="100" /></a> <a href="http://www.flickr.com/photos/garydunn808/9133403982/" title="BMW130609-12 by garydunn808, on Flickr"><img alt="BMW130609-12" height="67" src="http://farm4.staticflickr.com/3709/9133403982_e0ef81160b_t.jpg" width="100" /></a><br />
<a href="http://www.flickr.com/photos/garydunn808/9131189111/" title="BMW130609-13 by garydunn808, on Flickr"><img alt="BMW130609-13" height="67" src="http://farm3.staticflickr.com/2834/9131189111_65d42b5f67_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/9131189111/" title="BMW130609-13 by garydunn808, on Flickr"><img alt="BMW130609-13" height="67" src="http://farm3.staticflickr.com/2834/9131189111_65d42b5f67_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/9133398216/" title="BMW130609-14 by garydunn808, on Flickr"><img alt="BMW130609-14" height="67" src="http://farm4.staticflickr.com/3793/9133398216_7e56609718_t.jpg" width="100" /></a><br />
<a href="http://www.flickr.com/photos/garydunn808/9131183427/" title="BMW130609-15 by garydunn808, on Flickr"><img alt="BMW130609-15" height="67" src="http://farm6.staticflickr.com/5544/9131183427_86b3baa1e4_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/9131180929/" title="BMW130609-16 by garydunn808, on Flickr"><img alt="BMW130609-16" height="67" src="http://farm3.staticflickr.com/2844/9131180929_54f6e2aa9f_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/9133389966/" title="BMW130609-17 by garydunn808, on Flickr"><img alt="BMW130609-17" height="67" src="http://farm4.staticflickr.com/3791/9133389966_3d5622f008_t.jpg" width="100" /></a><br />
<a href="http://www.flickr.com/photos/garydunn808/9133386942/" title="BMW130609-18 by garydunn808, on Flickr"><img alt="BMW130609-18" height="67" src="http://farm4.staticflickr.com/3671/9133386942_77dc5b85df_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/9131172041/" title="BMW130609-19 by garydunn808, on Flickr"><img alt="BMW130609-19" height="67" src="http://farm4.staticflickr.com/3721/9131172041_93648192ba_t.jpg" width="100" /></a>Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0tag:blogger.com,1999:blog-5831132788099973832.post-34842391517311875222013-06-02T17:46:00.001-10:002013-06-02T17:53:24.410-10:00Painted door skins, ready to attachToday was a big step forward. I finally painted the inside of both door skins with gray POR-15. Also painted some spots on the door where drips would have interfered with attaching hardware later on. Patrick Casey told me about another local source for POR-15 products, Hi-Line Distributors on Ualena St. They had two 4 oz. cans of gray paint and I grabbed them last Friday.<br />
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Sanded the paint applied at the factory, to rough up the surface of the good parts and remove the bad parts. Used my orbital sander as much as possible but had to resort to hand sanding for the tight spots.<br />
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Next time I will attach the RH skin. That should be exciting!<br />
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<a href="http://www.flickr.com/photos/garydunn808/8932173450/" title="BMW130602-01 by garydunn808, on Flickr"><img alt="BMW130602-01" height="67" src="http://farm3.staticflickr.com/2806/8932173450_7bca31aaee_t.jpg" width="100" /></a><br />
<a href="http://www.flickr.com/photos/garydunn808/8932168304/" title="BMW130602-02 by garydunn808, on Flickr"><img alt="BMW130602-02" height="67" src="http://farm9.staticflickr.com/8534/8932168304_d8ccfef3f4_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/8932162302/" title="BMW130602-03 by garydunn808, on Flickr"><img alt="BMW130602-03" height="67" src="http://farm9.staticflickr.com/8403/8932162302_fbaa30603e_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/8931543485/" title="BMW130602-04 by garydunn808, on Flickr"><img alt="BMW130602-04" height="67" src="http://farm6.staticflickr.com/5338/8931543485_67d4ce678b_t.jpg" width="100" /></a><br />
<a href="http://www.flickr.com/photos/garydunn808/8932152354/" title="BMW130602-05 by garydunn808, on Flickr"><img alt="BMW130602-05" height="67" src="http://farm4.staticflickr.com/3714/8932152354_eaa56e3cf7_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/8931532587/" title="BMW130602-06 by garydunn808, on Flickr"><img alt="BMW130602-06" height="67" src="http://farm3.staticflickr.com/2823/8931532587_7cdd76f421_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/8932139902/" title="BMW130602-07 by garydunn808, on Flickr"><img alt="BMW130602-07" height="67" src="http://farm6.staticflickr.com/5460/8932139902_f27e2a3993_t.jpg" width="100" /></a>
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Last Sunday was Pattie's birthday party at Side Street Inn, and of course May 12th was Mother's Day. On the 19th I was still dealing with a leaky hot water heater but I did manage to bring in the Lotus battery for a charge. Didn't help, car still won't crank. Will take battery to Batter Bills for a test. The cassette water pump finally arrived, brought it to the shop.<br />
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<a href="http://www.flickr.com/photos/garydunn808/8756422082/" title="Lotus130519-01 by garydunn808, on Flickr"><img alt="Lotus130519-01" height="67" src="http://farm6.staticflickr.com/5330/8756422082_324f4667eb_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/8755299993/" title="Lotus130519-02 by garydunn808, on Flickr"><img alt="Lotus130519-02" height="67" src="http://farm9.staticflickr.com/8556/8755299993_5ef5e81a4a_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/8755298535/" title="Lotus130519-03 by garydunn808, on Flickr"><img alt="Lotus130519-03" height="67" src="http://farm8.staticflickr.com/7459/8755298535_889ed5e3f7_t.jpg" width="100" /></a><br />
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<br />Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0tag:blogger.com,1999:blog-5831132788099973832.post-83333751007717398952013-05-06T21:59:00.000-10:002013-05-06T21:59:26.530-10:00RH door window trim rough fitRain today so no painting. Besides, need to get more gray POR-15.<br />
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Too many drips along the edges where the skins will clamp to allow a good fit. Sanded down with block sander and 80# paper.<br />
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Worked on how window opening trim piece will fit. Factory spot welded top of skin and frame. Not sure this is necessary. At most I might epoxy them. Both are wedged inside the window trim, so any additional fastening seems like overkill. <a href="http://forums.bimmerforums.com/forum/showthread.php?1990590-Welding-along-top-of-new-door-skins" target="_blank">Posted this question on Bimmerforums</a>.<br />
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<a href="http://www.flickr.com/photos/garydunn808/8711838619/" title="BMW130505-01 by garydunn808, on Flickr"><img alt="BMW130505-01" height="67" src="http://farm9.staticflickr.com/8261/8711838619_13c7905552_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/8712962648/" title="BMW130505-02 by garydunn808, on Flickr"><img alt="BMW130505-02" height="67" src="http://farm9.staticflickr.com/8124/8712962648_a59ac9f893_t.jpg" width="100" /></a>
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Details of rubber and felt inserts, which I removed. Rubber destroyed.<br />
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<a href="http://www.flickr.com/photos/garydunn808/8712960762/" title="BMW130505-03 by garydunn808, on Flickr"><img alt="BMW130505-03" height="67" src="http://farm9.staticflickr.com/8408/8712960762_f599edcc06_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/8711833181/" title="BMW130505-04 by garydunn808, on Flickr"><img alt="BMW130505-04" height="67" src="http://farm9.staticflickr.com/8265/8711833181_024e1ea3ef_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/8712957368/" title="BMW130505-05 by garydunn808, on Flickr"><img alt="BMW130505-05" height="67" src="http://farm9.staticflickr.com/8542/8712957368_c84ffb5639_t.jpg" width="100" /></a><br />
<a href="http://www.flickr.com/photos/garydunn808/8711829655/" title="BMW130505-06 by garydunn808, on Flickr"><img alt="BMW130505-06" height="67" src="http://farm9.staticflickr.com/8275/8711829655_74d77ca2ee_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/8711827917/" title="BMW130505-07 by garydunn808, on Flickr"><img alt="BMW130505-07" height="67" src="http://farm9.staticflickr.com/8419/8711827917_429ed2d16e_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/8712952392/" title="BMW130505-08 by garydunn808, on Flickr"><img alt="BMW130505-08" height="67" src="http://farm9.staticflickr.com/8411/8712952392_8b9e359db3_t.jpg" width="100" /></a><br />
<a href="http://www.flickr.com/photos/garydunn808/8711824241/" title="BMW130505-09 by garydunn808, on Flickr"><img alt="BMW130505-09" height="67" src="http://farm9.staticflickr.com/8269/8711824241_76d1dc811f_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/8712948864/" title="BMW130505-10 by garydunn808, on Flickr"><img alt="BMW130505-10" height="67" src="http://farm9.staticflickr.com/8130/8712948864_b6295cf75e_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/8711820627/" title="BMW130505-11 by garydunn808, on Flickr"><img alt="BMW130505-11" height="67" src="http://farm9.staticflickr.com/8398/8711820627_5bb1860389_t.jpg" width="100" /></a><br />
<a href="http://www.flickr.com/photos/garydunn808/8711818913/" title="BMW130505-12 by garydunn808, on Flickr"><img alt="BMW130505-12" height="67" src="http://farm9.staticflickr.com/8393/8711818913_ec30cd1a24_t.jpg" width="100" /></a>
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Finger pointing to where skin edge and frame edge meet along top of window opening.<br />
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<a href="http://www.flickr.com/photos/garydunn808/8711792335/" title="BMW130505-26 by garydunn808, on Flickr"><img alt="BMW130505-26" height="67" src="http://farm9.staticflickr.com/8402/8711792335_c0857a5dac_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/8711789637/" title="BMW130505-27 by garydunn808, on Flickr"><img alt="BMW130505-27" height="67" src="http://farm9.staticflickr.com/8259/8711789637_81da94e1af_t.jpg" width="100" /></a>
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Window opening trim in place.<br />
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<a href="http://www.flickr.com/photos/garydunn808/8711787595/" title="BMW130505-28 by garydunn808, on Flickr"><img alt="BMW130505-28" height="67" src="http://farm9.staticflickr.com/8255/8711787595_7ea8b55af6_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/8711785511/" title="BMW130505-29 by garydunn808, on Flickr"><img alt="BMW130505-29" height="67" src="http://farm9.staticflickr.com/8266/8711785511_7b56c4433a_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/8712910088/" title="BMW130505-30 by garydunn808, on Flickr"><img alt="BMW130505-30" height="67" src="http://farm9.staticflickr.com/8394/8712910088_f4b75c16f5_t.jpg" width="100" /></a>
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<br />Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0tag:blogger.com,1999:blog-5831132788099973832.post-42403190292929815092013-04-30T19:48:00.000-10:002013-04-30T19:48:09.835-10:00Been awhile ...It has been way too long since I updated this blog. A lot has happened. Here are some highlights:<br />
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July 2012 - Took the family to California to visit my son Matt, first trip to the mainland for my younger son Mike. Rented an SUV and drive up through Monterey to San Francisco.<br />
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September 2012 - Honolulu Century Ride. Did the full hundred miles.<br />
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December 2012 - Ran the Honolulu Marathon for the first time.<br />
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February 2013 - My lovey E34 Touring was rear-ended, a total loss.<br />
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April 2013 - Finally found a replacement for my wagon, a 1989 E34 535i sedan. Rode the Haleiwa Metric Century Ride.<br />
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As May gets underway I will be training for my first triathlon, the Honolulu Tinman, on July 28th. That will definitely take a big chunk of my "free" time. However, I do intend to keep Sundays for cars. I will go into more detail on the E9 a little later. For now I must point out that the Lotus Europa has needed a water pump for a long time. In fact I ordered a replacement cassette kit from Dave Bean Engineering roughly a year ago thinking it would be my summer 2012 project. It just arrived! So look for a lot of work being done on the Lotus this summer.<br />
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That being said, I actually have spent a lot of time on the E9. I just have not taken time to write about it. Virtually all of the work has been on the doors. I am not going to chronicle the entire story here; I think the pics on Flickr tell the story well enough. I will say that I brushed on the second coat of POR-15 on the RH door, so now both are ready to have the skins installed. I am going to fiddle with it this weekend to see if I can install the skins without welding -- a bit of epoxy might do the trick. If so I can paint the inside before assembling, which will make a much more rust resistant product.<br />
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Here are a few selected pics of recent activity:<br />
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<a href="http://www.flickr.com/photos/garydunn808/8651179346/" title="BMW130120-09 by garydunn808, on Flickr"><img alt="BMW130120-09" height="67" src="http://farm9.staticflickr.com/8112/8651179346_e810295a60_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/8650162045/" title="BMW130303-01 by garydunn808, on Flickr"><img alt="BMW130303-01" height="67" src="http://farm9.staticflickr.com/8239/8650162045_d232ac3bfc_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/8651270788/" title="BMW130414-04 by garydunn808, on Flickr"><img alt="BMW130414-04" height="67" src="http://farm9.staticflickr.com/8126/8651270788_31ebf511ff_t.jpg" width="100" /></a><br />
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What really eats up the time is fabricating and welding patches. Here are a few more:<br />
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<a href="http://www.flickr.com/photos/garydunn808/8248104187/" title="BMW121125-02 by garydunn808, on Flickr"><img alt="BMW121125-02" height="67" src="http://farm9.staticflickr.com/8198/8248104187_67cdd9c385_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/8248102905/" title="BMW121125-03 by garydunn808, on Flickr"><img alt="BMW121125-03" height="67" src="http://farm9.staticflickr.com/8348/8248102905_6a9da4bacf_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/8248101685/" title="BMW121125-04 by garydunn808, on Flickr"><img alt="BMW121125-04" height="67" src="http://farm9.staticflickr.com/8347/8248101685_cbc217ab37_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/8249191002/" title="BMW121202-01 by garydunn808, on Flickr"><img alt="BMW121202-01" height="67" src="http://farm9.staticflickr.com/8490/8249191002_d35e4b6411_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/8249186698/" title="BMW121202-04 by garydunn808, on Flickr"><img alt="BMW121202-04" height="67" src="http://farm9.staticflickr.com/8202/8249186698_8eaecaf95e_t.jpg" width="100" /></a>Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0tag:blogger.com,1999:blog-5831132788099973832.post-31238566971400417942012-04-22T22:00:00.000-10:002012-04-22T23:45:59.725-10:00Door skins, part 4 - patch fabricationHaving used my Nikon 1 for a few weeks now I came to the conclusion that I needed a flash. Found it at the same place I bought the camera, Ritz at Ala Moana. Nicely integrated with the camera, and powered by the camera battery.<br />
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Looking over today's pics I am not happy with how some turned out. They are not sharp. My experience tells me that even a hand-held shot should be sharp, because the exposure comes from the flash, which is faster than a shutter speed of 1/1000. What I think is happening is that the V-1 computer sees that ambient light can furnish most of what is required, and reduces the intensity of the flash. Meaning that camera motion is still an issue. I will need to hold the camera better in the future, especially when ambient light is rather bright.<br />
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<a href="http://www.flickr.com/photos/garydunn808/7105201049/" title="BMW120422--01 by garydunn808, on Flickr"><img alt="BMW120422--01" height="67" src="http://farm8.staticflickr.com/7044/7105201049_61121ff777_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6959133810/" title="BMW120422--02 by garydunn808, on Flickr"><img alt="BMW120422--02" height="67" src="http://farm9.staticflickr.com/8022/6959133810_677552c97f_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6959135046/" title="BMW120422--03 by garydunn808, on Flickr"><img alt="BMW120422--03" height="67" src="http://farm8.staticflickr.com/7070/6959135046_2356212f56_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6959136200/" title="BMW120422--04 by garydunn808, on Flickr"><img alt="BMW120422--04" height="67" src="http://farm9.staticflickr.com/8024/6959136200_ab9979fa0b_t.jpg" width="100" /></a>
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On my way home after last week's session I realized I hadn't taken a picture of the door as it sat at the end of the day. So, my first order of business today was to take that picture. Four, actually. The first is with the top on the near side, the second is the other way around, followed by a couple views of the ends.<br />
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<a href="http://www.flickr.com/photos/garydunn808/7105206255/" title="BMW120422--05 by garydunn808, on Flickr"><img alt="BMW120422--05" height="67" src="http://farm8.staticflickr.com/7236/7105206255_deb89fee47_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7105207477/" title="BMW120422--06 by garydunn808, on Flickr"><img alt="BMW120422--06" height="67" src="http://farm9.staticflickr.com/8166/7105207477_33751097d1_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7105208613/" title="BMW120422--07 by garydunn808, on Flickr"><img alt="BMW120422--07" height="67" src="http://farm9.staticflickr.com/8016/7105208613_74bff7bdc4_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/7105209791/" title="BMW120422--08 by garydunn808, on Flickr"><img alt="BMW120422--08" height="67" src="http://farm9.staticflickr.com/8008/7105209791_06804b3a4b_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7105210991/" title="BMW120422--09 by garydunn808, on Flickr"><img alt="BMW120422--09" height="67" src="http://farm8.staticflickr.com/7081/7105210991_cc42947382_t.jpg" width="100" /></a>
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The patch I need to make will run along the top outside edge of the window opening. This is where the frame and the skin have a flange, or tab, facing upwards. A heavy chromed trim piece presses down onto this tab. The same piece holds the window glass cushion, made of felt glued to thin aluminum. I need to be sure my patch down not interfere with this trim piece, so I spent some time reviewing how it all fits together.<br />
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This short video is a hand-held scan along the trim piece in the photos above. Sometimes seeing something like this as a video reveals details that do not come across as easily in a still shot.<br />
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<a href="http://www.flickr.com/photos/garydunn808/6959343710/" title="BMW120422--12 by garydunn808, on Flickr"><img alt="BMW120422--12" height="67" src="http://farm8.staticflickr.com/7060/6959343710_797d097bf0_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7105415651/" title="BMW120422--13 by garydunn808, on Flickr"><img alt="BMW120422--13" height="67" src="http://farm9.staticflickr.com/8025/7105415651_727039d83e_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6959346026/" title="BMW120422--14 by garydunn808, on Flickr"><img alt="BMW120422--14" height="67" src="http://farm8.staticflickr.com/7069/6959346026_30bdd27a9a_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6959347164/" title="BMW120422--15 by garydunn808, on Flickr"><img alt="BMW120422--15" height="67" src="http://farm8.staticflickr.com/7248/6959347164_b87967e9ab_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7105419399/" title="BMW120422--16 by garydunn808, on Flickr"><img alt="BMW120422--16" height="67" src="http://farm9.staticflickr.com/8161/7105419399_4557200ee3_t.jpg" width="100" /></a>
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When I had my plan, all I had to do was lay out the patch, cut it, and flange it. The frame will be cut down by roughly 0.5 in. and the patch will overlap the remaining tab. The patch is flanged (used my pneumatic flanger) so that the new portion will be in-line with the old. The flange will go on the side away from the window.<br />
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Next step is to cut out sections of the patch to clear some bumps in the frame. I suspect a little more work will be required in the neighborhood of the outside door handle.Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0tag:blogger.com,1999:blog-5831132788099973832.post-88109859747153065432012-04-15T19:58:00.000-10:002012-04-22T22:30:41.960-10:00Door skins, part 3My goal for today was to figure out how to repair the top edge of the door. In the process I ended up removing all of what remained inside the door. Probably a good idea anyway, because of the welding that needs to be done.<br />
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I notice that with my new camera (Nikon 1) I take more pictures. I consider that a good thing. Why so many more? I'd say it is because of the larger monitor. I react to what I see, instead of hoping the one shot got what I wanted. Plus, it's fast. So, here are a lot of pics.<br />
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<a href="http://www.flickr.com/photos/garydunn808/7100361565/" title="BMW120415--01 by garydunn808, on Flickr"><img alt="BMW120415--01" height="67" src="http://farm6.staticflickr.com/5320/7100361565_ef7fe61877_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7100364021/" title="BMW120415--02 by garydunn808, on Flickr"><img alt="BMW120415--02" height="67" src="http://farm6.staticflickr.com/5276/7100364021_16e9d755e2_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7100365787/" title="BMW120415--03 by garydunn808, on Flickr"><img alt="BMW120415--03" height="67" src="http://farm8.staticflickr.com/7064/7100365787_1e375692ee_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6954298612/" title="BMW120415--04 by garydunn808, on Flickr"><img alt="BMW120415--04" height="67" src="http://farm6.staticflickr.com/5346/6954298612_3edc47cdf5_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6954300150/" title="BMW120415--05 by garydunn808, on Flickr"><img alt="BMW120415--05" height="67" src="http://farm8.staticflickr.com/7138/6954300150_022bb14fdd_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6954302006/" title="BMW120415--06 by garydunn808, on Flickr"><img alt="BMW120415--06" height="67" src="http://farm6.staticflickr.com/5031/6954302006_fa2bba26f3_t.jpg" width="100" /></a>
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My first challenge was to do something about the reinforcing doubler behind the door skin around the door handle. I used a cutoff wheel on a die grinder to cut away the door skin, trying to leave the doubler intact so that I can reuse it. You can see some wounds where I hit it while working blind. There is some rust in the area, including behind the doubler, but I think it can be treated.<br />
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<a href="http://www.flickr.com/photos/garydunn808/7100372369/" title="BMW120415--07 by garydunn808, on Flickr"><img alt="BMW120415--07" height="67" src="http://farm6.staticflickr.com/5348/7100372369_622aac55fb_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7100373731/" title="BMW120415--08 by garydunn808, on Flickr"><img alt="BMW120415--08" height="67" src="http://farm6.staticflickr.com/5470/7100373731_3e8fb0fd53_t.jpg" width="100" /></a>
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Had to remove some rubbery coating BMW put along the bottom edge of the door frame. It worked very well, except for where moisture got under the paint and rust formed under the coating. Removed with scraper and wiping with rag soaked with acetone.<br />
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<a href="http://www.flickr.com/photos/garydunn808/6954306186/" title="BMW120415--09 by garydunn808, on Flickr"><img alt="BMW120415--09" height="67" src="http://farm6.staticflickr.com/5453/6954306186_88527b7c8e_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6954307588/" title="BMW120415--10 by garydunn808, on Flickr"><img alt="BMW120415--10" height="67" src="http://farm6.staticflickr.com/5038/6954307588_8a328ca91f_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7100377867/" title="BMW120415--11 by garydunn808, on Flickr"><img alt="BMW120415--11" height="67" src="http://farm6.staticflickr.com/5272/7100377867_71a99ce681_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/7100379195/" title="BMW120415--12 by garydunn808, on Flickr"><img alt="BMW120415--12" height="67" src="http://farm8.staticflickr.com/7039/7100379195_c50e78bdd0_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6954312046/" title="BMW120415--13 by garydunn808, on Flickr"><img alt="BMW120415--13" height="67" src="http://farm6.staticflickr.com/5117/6954312046_2601e873a7_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7100386525/" title="BMW120415--17 by garydunn808, on Flickr"><img alt="BMW120415--17" height="67" src="http://farm6.staticflickr.com/5441/7100386525_866bc0a075_t.jpg" width="100" /></a>
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Removed the few remaining plastic plugs that are used to hold the interior panel. Not sure how many the factory implemented, most of mine were broken.<br />
<a href="http://www.flickr.com/photos/garydunn808/6954313468/" title="BMW120415--14 by garydunn808, on Flickr"><img alt="BMW120415--14" height="67" src="http://farm8.staticflickr.com/7071/6954313468_8877f51734_t.jpg" width="100" /></a>
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Found this channel on the bottom of the door. Probably held a rubber seal; no sign of that.<br />
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<a href="http://www.flickr.com/photos/garydunn808/6954314990/" title="BMW120415--15 by garydunn808, on Flickr"><img alt="BMW120415--15" height="67" src="http://farm6.staticflickr.com/5349/6954314990_8a35c38bd7_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7100385057/" title="BMW120415--16 by garydunn808, on Flickr"><img alt="BMW120415--16" height="67" src="http://farm8.staticflickr.com/7197/7100385057_a32070ce5b_t.jpg" width="100" /></a><br />
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This interior trim piece was attached by a single tiny Philips head screw.<br />
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<a href="http://www.flickr.com/photos/garydunn808/6954319450/" title="BMW120415--18 by garydunn808, on Flickr"><img alt="BMW120415--18" height="67" src="http://farm8.staticflickr.com/7098/6954319450_078b0f3ebc_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7100389271/" title="BMW120415--19 by garydunn808, on Flickr"><img alt="BMW120415--19" height="67" src="http://farm8.staticflickr.com/7066/7100389271_60142e6d31_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7100390759/" title="BMW120415--20 by garydunn808, on Flickr"><img alt="BMW120415--20" height="67" src="http://farm8.staticflickr.com/7250/7100390759_a0536cf48d_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/7100392291/" title="BMW120415--21 by garydunn808, on Flickr"><img alt="BMW120415--21" height="67" src="http://farm8.staticflickr.com/7124/7100392291_eaa6ea5ed6_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6954325752/" title="BMW120415--22 by garydunn808, on Flickr"><img alt="BMW120415--22" height="67" src="http://farm8.staticflickr.com/7110/6954325752_3fdbbfb04d_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6954327208/" title="BMW120415--23 by garydunn808, on Flickr"><img alt="BMW120415--23" height="67" src="http://farm8.staticflickr.com/7089/6954327208_37a86ef585_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6954328732/" title="BMW120415--24 by garydunn808, on Flickr"><img alt="BMW120415--24" height="67" src="http://farm8.staticflickr.com/7260/6954328732_5225289065_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7100398303/" title="BMW120415--25 by garydunn808, on Flickr"><img alt="BMW120415--25" height="67" src="http://farm6.staticflickr.com/5325/7100398303_47d29e2c64_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7100399853/" title="BMW120415--26 by garydunn808, on Flickr"><img alt="BMW120415--26" height="67" src="http://farm6.staticflickr.com/5240/7100399853_5317da2bde_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6954333228/" title="BMW120415--27 by garydunn808, on Flickr"><img alt="BMW120415--27" height="67" src="http://farm8.staticflickr.com/7083/6954333228_b52a194213_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6954334638/" title="BMW120415--28 by garydunn808, on Flickr"><img alt="BMW120415--28" height="67" src="http://farm8.staticflickr.com/7064/6954334638_95301e6732_t.jpg" width="100" /></a>
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Decided the door release mechanism had to come out. Note the one almost hidden bolt accessed through a hole in the door frame.<br />
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<a href="http://www.flickr.com/photos/garydunn808/7100404199/" title="BMW120415--29 by garydunn808, on Flickr"><img alt="BMW120415--29" height="67" src="http://farm8.staticflickr.com/7235/7100404199_316d0d69b6_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7100405857/" title="BMW120415--30 by garydunn808, on Flickr"><img alt="BMW120415--30" height="67" src="http://farm8.staticflickr.com/7280/7100405857_5962d3a2a4_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7100407597/" title="BMW120415--31 by garydunn808, on Flickr"><img alt="BMW120415--31" height="67" src="http://farm8.staticflickr.com/7234/7100407597_50fc3b17ac_t.jpg" width="100" /></a><br />
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Removed the rear window lift guide. Two extra thin nuts at the top, two bolts at the bottom bracket.Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0tag:blogger.com,1999:blog-5831132788099973832.post-59493355068420282912012-04-01T17:30:00.000-10:002012-04-08T23:30:55.602-10:00Door skins, part 2Good news! The shop is back to Sunday hours. That means I will be working on Sundays and can stay longer. Of course, the 8th is Easter, but after that the schedule should smooth out.<br />
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<a href="http://www.flickr.com/photos/garydunn808/7059910241/" title="BMW120401--01 by garydunn808, on Flickr"><img alt="BMW120401--01" height="67" src="http://farm6.staticflickr.com/5449/7059910241_1d90bf9e57_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7059911689/" title="BMW120401--02 by garydunn808, on Flickr"><img alt="BMW120401--02" height="67" src="http://farm6.staticflickr.com/5039/7059911689_3d25979453_t.jpg" width="100" /></a>
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I began where I left off, peeling back the door skin. Originally I used a standard pliers, but I discovered that medium sized slip joint pliers provide better leverage.<br />
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<a href="http://www.flickr.com/photos/garydunn808/7059913159/" title="BMW120401--03 by garydunn808, on Flickr"><img alt="BMW120401--03" height="67" src="http://farm6.staticflickr.com/5328/7059913159_b276ba7c7f_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6913831562/" title="BMW120401--04 by garydunn808, on Flickr"><img alt="BMW120401--04" height="67" src="http://farm8.staticflickr.com/7247/6913831562_dcb784ac33_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6913833116/" title="BMW120401--05 by garydunn808, on Flickr"><img alt="BMW120401--05" height="67" src="http://farm6.staticflickr.com/5117/6913833116_7163960bea_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6913834428/" title="BMW120401--06 by garydunn808, on Flickr"><img alt="BMW120401--06" height="67" src="http://farm8.staticflickr.com/7128/6913834428_f6a97795e6_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7059919191/" title="BMW120401--07 by garydunn808, on Flickr"><img alt="BMW120401--07" height="67" src="http://farm8.staticflickr.com/7056/7059919191_8abe25d9e8_t.jpg" width="100" /></a>
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Found two places where the door skin was brazed to the frame. Both are near the top, between where the edge wraps around and where it is spot welded to the window opening. One at the front, on at the rear.<br />
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<a href="http://www.flickr.com/photos/garydunn808/6913837536/" title="BMW120401--08 by garydunn808, on Flickr"><img alt="BMW120401--08" height="67" src="http://farm8.staticflickr.com/7185/6913837536_a15311d908_t.jpg" width="100" /></a>
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Rather than grind away all the spot welds along the top edge I decided to cut through the skin with a cutting wheel.<br />
<a href="http://www.flickr.com/photos/garydunn808/7059921867/" title="BMW120401--09 by garydunn808, on Flickr"><img alt="BMW120401--09" height="67" src="http://farm8.staticflickr.com/7229/7059921867_e3d84f5b8d_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7059923179/" title="BMW120401--10 by garydunn808, on Flickr"><img alt="BMW120401--10" height="67" src="http://farm8.staticflickr.com/7062/7059923179_4444b542a2_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6913841290/" title="BMW120401--11 by garydunn808, on Flickr"><img alt="BMW120401--11" height="67" src="http://farm8.staticflickr.com/7239/6913841290_4a6702545c_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6913842616/" title="BMW120401--12 by garydunn808, on Flickr"><img alt="BMW120401--12" height="67" src="http://farm6.staticflickr.com/5322/6913842616_6a5e4d9f43_t.jpg" width="100" /></a>
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Even then the skin would not come free. Problem was the door handle mechanism. Hard to see, but it appeared to be attached to the door skin. Removed some the the mechanism, but ended up cutting around it.<br />
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<a href="http://www.flickr.com/photos/garydunn808/7059926953/" title="BMW120401--13 by garydunn808, on Flickr"><img alt="BMW120401--13" height="67" src="http://farm8.staticflickr.com/7257/7059926953_a56519f9f0_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7059928161/" title="BMW120401--14 by garydunn808, on Flickr"><img alt="BMW120401--14" height="67" src="http://farm8.staticflickr.com/7088/7059928161_6319a94451_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6913846350/" title="BMW120401--15 by garydunn808, on Flickr"><img alt="BMW120401--15" height="67" src="http://farm8.staticflickr.com/7211/6913846350_707d67ef97_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/7059930783/" title="BMW120401--16 by garydunn808, on Flickr"><img alt="BMW120401--16" height="67" src="http://farm8.staticflickr.com/7276/7059930783_0c76de1632_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7059931903/" title="BMW120401--17 by garydunn808, on Flickr"><img alt="BMW120401--17" height="67" src="http://farm6.staticflickr.com/5119/7059931903_d9b0542f76_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6913850090/" title="BMW120401--18 by garydunn808, on Flickr"><img alt="BMW120401--18" height="67" src="http://farm8.staticflickr.com/7260/6913850090_7583ed8774_t.jpg" width="100" /></a>
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After the door skin was off I decided to split the piece over the door handle to see what was underneath. Still not sure how the doubler is attached, appears that one end is attached to the frame and the other end to the door skin. Looks like I will need to remove from old skin and attach to new skin.Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0tag:blogger.com,1999:blog-5831132788099973832.post-65536648252492970862012-03-25T18:19:00.000-10:002012-03-25T18:20:27.083-10:00E34 oil change, door skins part 1.1<div xmlns="http://www.w3.org/1999/xhtml">
<a href="http://www.flickr.com/photos/garydunn808/6870239712/" title="E34120324-01 by garydunn808, on Flickr"><img alt="E34120324-01" height="67" src="http://farm8.staticflickr.com/7136/6870239712_29742a185d_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7016350591/" title="E34120324-02 by garydunn808, on Flickr"><img alt="E34120324-02" height="67" src="http://farm8.staticflickr.com/7206/7016350591_fb6253ff87_t.jpg" width="100" /></a>
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Most of today's session was taken up by an oil change on the E34. First time for that car, so it took me an hour. The Fram replacement cartridge came with oil rings for the cover and the cover bolt, and two crush washers for the cover bolt and the drain plug. Filled with same oil the po was using, Mobile 1 15w50. Reset the computer with my new Polk scanner.<br />
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I spent what little time remained on the E9, prying off the door skin. Finished the bottom edge. Got better results with some channel lock pliers.<br />
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My E34 was in the bay next to my E9, and on the other side was a mid-2000s M3. Just outside was a late model 530, getting new tires. So naturally we all wasted some time admiring each others rides and swapping car tales. <br />
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Had to leave early to do packet pickup for tomorrow's 10k run in Kailua. Sorry to say their packet pickup was as messed up as everyone else's. Seems like a job opportunity, a professional packet pickup contractor.<br />
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posted from <a href="https://market.android.com/details?id=pl.przemelek.android.blogger">Bloggeroid</a></div>
</div>Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0tag:blogger.com,1999:blog-5831132788099973832.post-42098765523760071422012-03-17T23:20:00.000-10:002012-03-21T23:22:31.808-10:00New camera, door skins part 1We will have a guest artist spending a week with the U.H. Gamelan, giving a bunch of lessons, and I decided that I wanted to video my sessions. My old Nikon 5400 can shoot video, but it is low res 4:3 and the battery is going. Time to buy a new camera. Okay, an excuse. Been looking for months and wanted a Nikon 1. Now I had to choose between the U1 and the V1, decided to go with the V1. Still learning how to use it, including how to upload to Flickr. I have been reducing the image size from the 5400 to 800x600, plenty good enough for this blog, but so far I have not figured out how to do that for the V1, so these pics are full size.<br />
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<a href="http://www.flickr.com/photos/garydunn808/6859021764/" title="BMW120318--01 by garydunn808, on Flickr"><img alt="BMW120318--01" height="67" src="http://farm8.staticflickr.com/7080/6859021764_ab8a2d1750_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6859022560/" title="BMW120318--02 by garydunn808, on Flickr"><img alt="BMW120318--02" height="67" src="http://farm8.staticflickr.com/7055/6859022560_7a4fae480d_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6859023494/" title="BMW120318--03 by garydunn808, on Flickr"><img alt="BMW120318--03" height="67" src="http://farm8.staticflickr.com/7213/6859023494_f3d243ff9c_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/7005142299/" title="BMW120318--04 by garydunn808, on Flickr"><img alt="BMW120318--04" height="67" src="http://farm8.staticflickr.com/7257/7005142299_94f424a38f_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7005143125/" title="BMW120318--05 by garydunn808, on Flickr"><img alt="BMW120318--05" height="67" src="http://farm8.staticflickr.com/7239/7005143125_23b4954d19_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7005143921/" title="BMW120318--06 by garydunn808, on Flickr"><img alt="BMW120318--06" height="67" src="http://farm7.staticflickr.com/6051/7005143921_0a364ea7ca_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6859041826/" title="BMW120318--07 by garydunn808, on Flickr"><img alt="BMW120318--07" height="67" src="http://farm7.staticflickr.com/6095/6859041826_079d9be849_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7005161007/" title="BMW120318--08 by garydunn808, on Flickr"><img alt="BMW120318--08" height="67" src="http://farm7.staticflickr.com/6049/7005161007_34de4d0a6f_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/7005161907/" title="BMW120318--09 by garydunn808, on Flickr"><img alt="BMW120318--09" height="67" src="http://farm8.staticflickr.com/7078/7005161907_201e99a83d_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7005162669/" title="BMW120318--10 by garydunn808, on Flickr"><img alt="BMW120318--10" height="67" src="http://farm8.staticflickr.com/7140/7005162669_6e8d9febfd_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6859045016/" title="BMW120318--11 by garydunn808, on Flickr"><img alt="BMW120318--11" height="67" src="http://farm8.staticflickr.com/7205/6859045016_6606ba0d3f_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6859045906/" title="BMW120318--12 by garydunn808, on Flickr"><img alt="BMW120318--12" height="67" src="http://farm7.staticflickr.com/6225/6859045906_75d868f745_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6859046654/" title="BMW120318--13 by garydunn808, on Flickr"><img alt="BMW120318--13" height="67" src="http://farm8.staticflickr.com/7222/6859046654_703d126c3e_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/7005165967/" title="BMW120318--14 by garydunn808, on Flickr"><img alt="BMW120318--14" height="67" src="http://farm8.staticflickr.com/7066/7005165967_a52990ca71_t.jpg" width="100" /></a>
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Decided that since the door skins are here I should dig into the doors, and come back to the floor. Comparing the skin to the actual door I found some things to do before removing the old skin. Removed two rubber pads that act as stops for the door handle. Removed the lock, and the side mirror mount. Measured the spacing of the holes for the trim:<br />
<br />
LH door<br />
<br />
#1 5/8 in. from fwd edge<br />
<br />
#2 7 1/2 in. from #1<br />
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#3 9 3/8 in. from #2<br />
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#4 9 3/8 in.<br />
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#5 9 7/16 in.<br />
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#6 5/16 in. from rear edge<br />
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Last but not least, I got started peeling back the lip of the door skin. I must admit that by the time I had to leave, my hand was tired and sore from working the pliers. Hopefully I will get one off next Saturday.Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0tag:blogger.com,1999:blog-5831132788099973832.post-20420324677466966982012-03-10T22:14:00.000-10:002012-03-21T22:22:30.497-10:00Not giving upSo maybe I was having a bad day. Stuff at work. Training hard -- cycling and running, that is. For whatever reason, the accumulation of setbacks seemed like too much to take on. So I decided to abandon this project.<br />
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Time passed. A few days. I discussed my decision with friends and got a lot of encouragement to keep going. So I decided I was back in the game.<br />
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<a href="http://www.flickr.com/photos/garydunn808/6859076018/" title="BMW120310-01 by garydunn808, on Flickr"><img alt="BMW120310-01" height="75" src="http://farm8.staticflickr.com/7094/6859076018_deabc5a092_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6859076026/" title="BMW120310-02 by garydunn808, on Flickr"><img alt="BMW120310-02" height="75" src="http://farm8.staticflickr.com/7208/6859076026_63619733f3_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6859076028/" title="BMW120310-03 by garydunn808, on Flickr"><img alt="BMW120310-03" height="75" src="http://farm8.staticflickr.com/7134/6859076028_243aa0e4e4_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6859076030/" title="BMW120310-04 by garydunn808, on Flickr"><img alt="BMW120310-04" height="75" src="http://farm7.staticflickr.com/6218/6859076030_7ec92f32c0_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6859076040/" title="BMW120310-05 by garydunn808, on Flickr"><img alt="BMW120310-05" height="75" src="http://farm8.staticflickr.com/7042/6859076040_e4c78c4f48_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6859076042/" title="BMW120310-06 by garydunn808, on Flickr"><img alt="BMW120310-06" height="75" src="http://farm7.staticflickr.com/6118/6859076042_e022692dc6_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6859081054/" title="BMW120310-07 by garydunn808, on Flickr"><img alt="BMW120310-07" height="75" src="http://farm7.staticflickr.com/6215/6859081054_e56c76653b_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6859081058/" title="BMW120310-08 by garydunn808, on Flickr"><img alt="BMW120310-08" height="75" src="http://farm7.staticflickr.com/6044/6859081058_591ea6a1f6_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6859081062/" title="BMW120310-09 by garydunn808, on Flickr"><img alt="BMW120310-09" height="75" src="http://farm8.staticflickr.com/7232/6859081062_875144e4ec_t.jpg" width="100" /></a>
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The next Saturday, my birthday, the door skins had arrived from England. Got them from a terrific restoration shop, Classic Heros. Love their address:<br />
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Coles Hall Barn<br />
Five Ashes<br />
Mayfield<br />
<br />
I can just see Bilbo and Samwise walking through the meadow.<br />
<br />
As I unpacked the door skins, wrapped in a lifetime supply of bubble wrap, I noticed many little spots where the primer was worn or scratched. In other places this would not pose a problem, but in Hawaii that bare steel will start to rust right away. I wanted to cover the bare spots with enamel, to really keep to moisture out, but it was raining so I could not shoot paint outside, and there was a nice car in the next stall. I wiped all the bare spots with Acetone, then shot them with POR-15 etching primer and called it a day.<br />
<br />
<br />Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0tag:blogger.com,1999:blog-5831132788099973832.post-22195206099779824012012-03-03T21:55:00.002-10:002012-03-03T21:57:44.156-10:00Time to give it up<a href="http://www.flickr.com/photos/garydunn808/6951240753/" title="BMW120303-01 by garydunn808, on Flickr"><img alt="BMW120303-01" height="75" src="http://farm8.staticflickr.com/7176/6951240753_56fa7830d4_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6951240755/" title="BMW120303-02 by garydunn808, on Flickr"><img alt="BMW120303-02" height="75" src="http://farm8.staticflickr.com/7193/6951240755_ff96a23f5c_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6951240757/" title="BMW120303-03 by garydunn808, on Flickr"><img alt="BMW120303-03" height="75" src="http://farm8.staticflickr.com/7178/6951240757_62b9e6a4ba_t.jpg" width="100" /></a>
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Today began with removing the tar from the inboard section of the driver's side floor. As I went along and exposed more of the damaged areas I realized that the second floor removed last week was the original floor. BMW used two layers here. What looked like good floor was the lower, external portion. Also alarming was the extent of rust along the top of the U-channel that runs under the floor. The damage was so bad I could see how it could contribute any strength.
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<a href="http://www.flickr.com/photos/garydunn808/6951240761/" title="BMW120303-04 by garydunn808, on Flickr"><img alt="BMW120303-04" height="75" src="http://farm8.staticflickr.com/7199/6951240761_880dd5892d_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6951240763/" title="BMW120303-05 by garydunn808, on Flickr"><img alt="BMW120303-05" height="75" src="http://farm8.staticflickr.com/7190/6951240763_a636ed64c7_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6951240771/" title="BMW120303-06 by garydunn808, on Flickr"><img alt="BMW120303-06" height="75" src="http://farm8.staticflickr.com/7200/6951240771_4b3426e03a_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6951242133/" title="BMW120303-07 by garydunn808, on Flickr"><img alt="BMW120303-07" height="75" src="http://farm8.staticflickr.com/7195/6951242133_3faefceace_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6951242137/" title="BMW120303-08 by garydunn808, on Flickr"><img alt="BMW120303-08" height="75" src="http://farm8.staticflickr.com/7038/6951242137_82ebec1a7b_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6951242139/" title="BMW120303-09 by garydunn808, on Flickr"><img alt="BMW120303-09" height="75" src="http://farm8.staticflickr.com/7047/6951242139_9610e3b1a4_t.jpg" width="100" /></a>
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While I worked I began to plan how I would repair those large holes. Obviously these would require welding. Then I spotted something along the lower edge of the smalled hole roughly in line with the gear shift. I lifted the car and looked underneath, and to my dismay I could see that this was the rear transmission mounting bracket, a U-channel welded to the floor. With so much rust damage this mount has lost its integrity, and repairing it would require some advanced sheet metal shaping and skilled welding. All this while retaining the alignment of the mounting point. Not easy.<br />
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Then I spotted more trouble. A big rust-through on the underneath floor in the area of the rear seat floor. And the tell-tale pattern of pop-rivets, indicating another cheap patch job on the rear floor. I could just make out that the floor here was also a double section, and that it served as the mounting point for the rubber drive shaft bushing. In other words, a second structural area, a load bearing point.<br />
<br />
Already these discoveries were serious, but then I added up what I had found in recent weeks. Recall that after finishing the nose I thought the only big deal remaining were the door skins. While preparing the doors for re-skinning I found damage along the top edges, tricky to repair. Extensive rust in the kink panels, enough to make me question their ability to hold up the doors. Poorly done repairs to both fender wells. Heavy rust around the heater mount. Several poor quality repairs to the floors. Even when the body is done, I will need to redo the interior, including all of the wood. Add it all up and it comes to more than I want to take on, given how long it has taken me to get to this point. To top it off, the Lotus needs a lot of work, and has been ignored while I concentrated on the E9.<br />
<br />
For all these reasons I have decided to abandon this project. This car has had a hard life, made worse by poor quality repairs that concealed the damage rather than repair it. Enough is enough. Time to move on.<br />
<br />Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0tag:blogger.com,1999:blog-5831132788099973832.post-30750688677327321192012-02-25T21:15:00.000-10:002012-03-03T21:16:29.788-10:00Driver's side (rotten) floor(s)<div xmlns="http://www.w3.org/1999/xhtml">
<a href="http://www.flickr.com/photos/garydunn808/6951103523/" title="BMW120225-01 by garydunn808, on Flickr"><img alt="BMW120225-01" height="75" src="http://farm8.staticflickr.com/7068/6951103523_1e7df3ff33_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6951103527/" title="BMW120225-02 by garydunn808, on Flickr"><img alt="BMW120225-02" height="75" src="http://farm8.staticflickr.com/7036/6951103527_97b1aa0e3c_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6951103529/" title="BMW120225-03 by garydunn808, on Flickr"><img alt="BMW120225-03" height="75" src="http://farm8.staticflickr.com/7068/6951103529_7f967e9046_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6951103533/" title="BMW120225-04 by garydunn808, on Flickr"><img alt="BMW120225-04" height="75" src="http://farm8.staticflickr.com/7189/6951103533_dc349db5bd_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6951103535/" title="BMW120225-05 by garydunn808, on Flickr"><img alt="BMW120225-05" height="75" src="http://farm8.staticflickr.com/7050/6951103535_099fd4b7b2_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6951103543/" title="BMW120225-06 by garydunn808, on Flickr"><img alt="BMW120225-06" height="75" src="http://farm8.staticflickr.com/7203/6951103543_092ea35678_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6804995648/" title="BMW120225-07 by garydunn808, on Flickr"><img alt="BMW120225-07" height="75" src="http://farm8.staticflickr.com/7184/6804995648_6a3548a3d3_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6804995654/" title="BMW120225-08 by garydunn808, on Flickr"><img alt="BMW120225-08" height="75" src="http://farm8.staticflickr.com/7196/6804995654_8959a35592_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6804995660/" title="BMW120225-09 by garydunn808, on Flickr"><img alt="BMW120225-09" height="75" src="http://farm8.staticflickr.com/7056/6804995660_dde915f26f_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6804995670/" title="BMW120225-10 by garydunn808, on Flickr"><img alt="BMW120225-10" height="75" src="http://farm8.staticflickr.com/7208/6804995670_90972313ba_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6804995672/" title="BMW120225-11 by garydunn808, on Flickr"><img alt="BMW120225-11" height="75" src="http://farm8.staticflickr.com/7036/6804995672_6181ea9af9_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6804995676/" title="BMW120225-12 by garydunn808, on Flickr"><img alt="BMW120225-12" height="75" src="http://farm8.staticflickr.com/7036/6804995676_c2d4d12700_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6804997632/" title="BMW120225-13 by garydunn808, on Flickr"><img alt="BMW120225-13" height="75" src="http://farm8.staticflickr.com/7202/6804997632_4645bc96ee_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6804997638/" title="BMW120225-14 by garydunn808, on Flickr"><img alt="BMW120225-14" height="75" src="http://farm8.staticflickr.com/7038/6804997638_9f19a3ac7b_t.jpg" width="100" /></a><br />
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The passenger's side floor was bad, but to me the left side seems even worse. Last week I almost got the left floor out. By that I mean the pop-riveted in repair panel. Today I got it out.<br />
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I saw that it would be easier to get the floor out if I removed the rubber (?) transmission tunnel cover. The bottom edge overlapped the floor, and the whole thing looked like it was ready to fall apart. Found a layer of foam rubber under the heavy rubber. Under that, in some places, was a layer of really stiff mystery muck. I decided to leave that alone.<br />
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<a href="http://www.flickr.com/photos/garydunn808/6804997650/" title="BMW120225-15 by garydunn808, on Flickr"><img alt="BMW120225-15" height="75" src="http://farm8.staticflickr.com/7194/6804997650_cb35252a05_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6804997652/" title="BMW120225-16 by garydunn808, on Flickr"><img alt="BMW120225-16" height="75" src="http://farm8.staticflickr.com/7187/6804997652_a201e8c6c3_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6804997656/" title="BMW120225-17 by garydunn808, on Flickr"><img alt="BMW120225-17" height="75" src="http://farm8.staticflickr.com/7197/6804997656_38003f1970_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6804997658/" title="BMW120225-18 by garydunn808, on Flickr"><img alt="BMW120225-18" height="75" src="http://farm8.staticflickr.com/7053/6804997658_f43ec10d32_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6951112883/" title="BMW120225-19 by garydunn808, on Flickr"><img alt="BMW120225-19" height="75" src="http://farm8.staticflickr.com/7182/6951112883_f596a1a18a_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6951112887/" title="BMW120225-20 by garydunn808, on Flickr"><img alt="BMW120225-20" height="75" src="http://farm8.staticflickr.com/7205/6951112887_d0456647a9_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6951112893/" title="BMW120225-21 by garydunn808, on Flickr"><img alt="BMW120225-21" height="75" src="http://farm8.staticflickr.com/7057/6951112893_d5a03ae5c7_t.jpg" width="100" /></a><br />
<a href="http://www.flickr.com/photos/garydunn808/6951112895/" title="BMW120225-22 by garydunn808, on Flickr"><img alt="BMW120225-22" height="75" src="http://farm8.staticflickr.com/7055/6951112895_72fbd8d62c_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6951112899/" title="BMW120225-23 by garydunn808, on Flickr"><img alt="BMW120225-23" height="75" src="http://farm8.staticflickr.com/7202/6951112899_ca61d5eb2a_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6951112901/" title="BMW120225-24 by garydunn808, on Flickr"><img alt="BMW120225-24" height="75" src="http://farm8.staticflickr.com/7202/6951112901_380b3d4eb0_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6805000600/" title="BMW120225-25 by garydunn808, on Flickr"><img alt="BMW120225-25" height="75" src="http://farm8.staticflickr.com/7186/6805000600_672597024b_t.jpg" width="100" /></a>
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<br />
Much to my surprise there was another rotten mess underneath. Where the right side had a thick layer of tar, the outer half of the left floor was rubble. When I removed that I found original floor, which doesn't look all that bad.<br />
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<div align="right" style="font-size: xx-small;">
posted from <a href="https://market.android.com/details?id=pl.przemelek.android.blogger">Bloggeroid</a></div>
</div>Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0tag:blogger.com,1999:blog-5831132788099973832.post-66158754826825022222012-02-18T18:54:00.000-10:002012-02-18T18:54:34.345-10:00Driver's seat out, floor almost out<div xmlns="http://www.w3.org/1999/xhtml">
Having ascertained the condition of the passengers side floor -- not good -- I decided today was the day to explore the other side. The work went much faster, a natural result of having done it once. I found the same shoddy floor repair panel and was trying to get it removed, but ran out of time.<br />
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<a href="http://www.flickr.com/photos/garydunn808/6900439799/" title="BMW120218-01 by garydunn808, on Flickr"><img alt="BMW120218-01" height="75" src="http://farm8.staticflickr.com/7181/6900439799_8d71a39bab_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6900439801/" title="BMW120218-02 by garydunn808, on Flickr"><img alt="BMW120218-02" height="75" src="http://farm8.staticflickr.com/7195/6900439801_c9a0d09f1b_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6900439803/" title="BMW120218-03 by garydunn808, on Flickr"><img alt="BMW120218-03" height="75" src="http://farm8.staticflickr.com/7183/6900439803_e307ddfb40_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6900439817/" title="BMW120218-04 by garydunn808, on Flickr"><img alt="BMW120218-04" height="75" src="http://farm8.staticflickr.com/7063/6900439817_569f7da527_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6900439819/" title="BMW120218-05 by garydunn808, on Flickr"><img alt="BMW120218-05" height="75" src="http://farm8.staticflickr.com/7039/6900439819_22c04d6ff5_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6900439823/" title="BMW120218-06 by garydunn808, on Flickr"><img alt="BMW120218-06" height="75" src="http://farm8.staticflickr.com/7042/6900439823_ee0700aa24_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6900445525/" title="BMW120218-07 by garydunn808, on Flickr"><img alt="BMW120218-07" height="75" src="http://farm8.staticflickr.com/7177/6900445525_d37f55e6a7_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6900445539/" title="BMW120218-08 by garydunn808, on Flickr"><img alt="BMW120218-08" height="75" src="http://farm8.staticflickr.com/7039/6900445539_153e3c9192_t.jpg" width="100" /></a>
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Found $3.96 is loose change under the rear carpet, and a Honolulu newspaper from 1999 under the front carpet. What was that for?<br />
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<a href="http://www.flickr.com/photos/garydunn808/6900445545/" title="BMW120218-09 by garydunn808, on Flickr"><img alt="BMW120218-09" height="75" src="http://farm8.staticflickr.com/7195/6900445545_dfa6338725_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6900445551/" title="BMW120218-10 by garydunn808, on Flickr"><img alt="BMW120218-10" height="75" src="http://farm8.staticflickr.com/7064/6900445551_9c88df3026_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6900445555/" title="BMW120218-11 by garydunn808, on Flickr"><img alt="BMW120218-11" height="75" src="http://farm8.staticflickr.com/7046/6900445555_2c6823034f_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6900445565/" title="BMW120218-12 by garydunn808, on Flickr"><img alt="BMW120218-12" height="75" src="http://farm8.staticflickr.com/7199/6900445565_709cd6dbed_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6900448745/" title="BMW120218-13 by garydunn808, on Flickr"><img alt="BMW120218-13" height="75" src="http://farm8.staticflickr.com/7188/6900448745_81e48765dc_t.jpg" width="100" /></a>
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The funny part was how the original gas pedal mount was accommodated. After pop-riveting in the new floor, having cut out the original mount, they riveted what used to be the old floor to another piece of sheet metal, then riveted that to the new floor. No sign of rust prevention. The original piece is all but disintegrated. I'll need to get creative to repair this.<br />
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posted from <a href="https://market.android.com/details?id=pl.przemelek.android.blogger">Bloggeroid</a></div>
</div>Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0tag:blogger.com,1999:blog-5831132788099973832.post-11515294583833351332012-02-11T18:24:00.000-10:002012-02-12T18:40:06.081-10:00Removed the tar, found a lost eco-system<a href="http://www.flickr.com/photos/garydunn808/6867178343/" title="BMW120212-01 by garydunn808, on Flickr"><img alt="BMW120212-01" height="75" src="http://farm8.staticflickr.com/7051/6867178343_b536589f90_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6867178351/" title="BMW120212-02 by garydunn808, on Flickr"><img alt="BMW120212-02" height="75" src="http://farm8.staticflickr.com/7193/6867178351_33ccc1943d_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6867178361/" title="BMW120212-03 by garydunn808, on Flickr"><img alt="BMW120212-03" height="75" src="http://farm8.staticflickr.com/7181/6867178361_d9e42d9ba2_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6867351461/" title="BMW120212-05 by garydunn808, on Flickr"><img alt="BMW120212-05" height="75" src="http://farm8.staticflickr.com/7177/6867351461_afe7be55d9_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6867351469/" title="BMW120212-06 by garydunn808, on Flickr"><img alt="BMW120212-06" height="75" src="http://farm8.staticflickr.com/7040/6867351469_1fb8a66037_t.jpg" width="100" /></a>
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This was one of those days when I felt like an archaeologist on a dig in ancient ruins. I set out to experiment using my Craftsman Multi-Tool to remove the thick layer of tar covering the passenger's floor. Worked well. A bit slow at first, but after the scraper blade warmed up from the friction the tar would melt and progress was much more rapid. After that the only problem was tar build-up on the blade. I made a video of the tool at work, at the bottom of this post. It works a lot better than a held held putty knife.<br />
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<a href="http://www.flickr.com/photos/garydunn808/6867351471/" title="BMW120212-07 by garydunn808, on Flickr"><img alt="BMW120212-07" height="75" src="http://farm8.staticflickr.com/7184/6867351471_ed3fec8b2f_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6867351479/" title="BMW120212-08 by garydunn808, on Flickr"><img alt="BMW120212-08" height="75" src="http://farm8.staticflickr.com/7046/6867351479_634f937453_t.jpg" width="100" /></a>
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Not long after starting I dug up a rubber plug. There was another just like it under the first. Eventually I pulled it out and could see the shop floor through the neat hole. Must have been a factory drain hole.<br />
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A little later I found a seam. As the sheet metal was exposed I could make out the outline of yet another patch. This was was professionally welded in, unlike the entire floor already removed, and the patches I can see at the rear side of the front wheel well. Obviously this coupe sat out in the rain a lot, leaky rubber window seal and all. That, or a PO enjoyed driving around with the windows down regardless of the weather, something I can sympathize with having driven this car on Hawaiian rainy days. That is when you really miss air conditioning.<br />
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There is still a thin layer of tar which will take a lot of elbow grease to remove. Along with a pile of rags and a large bottle of acetone. Next time. I did spray the entire area with POR-15 Metal Ready, to stop the rust from spreading.
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<embed type="application/x-shockwave-flash" src="http://www.flickr.com/apps/video/stewart.swf?v=109786" bgcolor="#000000" allowfullscreen="true" flashvars="intl_lang=en-us&photo_secret=e4b0616756&photo_id=6867301305" height="300" width="400"></embed></object>Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0tag:blogger.com,1999:blog-5831132788099973832.post-44252608462838191882012-02-04T22:46:00.001-10:002012-02-04T22:47:14.574-10:00Got the heater out<div xmlns="http://www.w3.org/1999/xhtml">
<a href="http://www.flickr.com/photos/garydunn808/6821560215/" title="BMW120204-01 by garydunn808, on Flickr"><img alt="BMW120204-01" height="75" src="http://farm8.staticflickr.com/7171/6821560215_e16127536b_t.jpg" width="100" /></a><br />
<a href="http://www.flickr.com/photos/garydunn808/6821560225/" title="BMW120204-02 by garydunn808, on Flickr"><img alt="BMW120204-02" height="75" src="http://farm8.staticflickr.com/7153/6821560225_fa1d01a464_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6821560231/" title="BMW120204-03 by garydunn808, on Flickr"><img alt="BMW120204-03" height="75" src="http://farm8.staticflickr.com/7156/6821560231_8c23692e9b_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6821560233/" title="BMW120204-04 by garydunn808, on Flickr"><img alt="BMW120204-04" height="75" src="http://farm8.staticflickr.com/7153/6821560233_0377431cca_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6821560241/" title="BMW120204-05 by garydunn808, on Flickr"><img alt="BMW120204-05" height="75" src="http://farm8.staticflickr.com/7148/6821560241_f970580384_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6821560245/" title="BMW120204-06 by garydunn808, on Flickr"><img alt="BMW120204-06" height="75" src="http://farm8.staticflickr.com/7153/6821560245_34c26cc74a_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6821563265/" title="BMW120204-07 by garydunn808, on Flickr"><img alt="BMW120204-07" height="75" src="http://farm8.staticflickr.com/7005/6821563265_6195935a6c_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6821563267/" title="BMW120204-08 by garydunn808, on Flickr"><img alt="BMW120204-08" height="75" src="http://farm8.staticflickr.com/7164/6821563267_c675880d24_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6821563271/" title="BMW120204-09 by garydunn808, on Flickr"><img alt="BMW120204-09" height="75" src="http://farm8.staticflickr.com/7172/6821563271_b0ffb0d4c0_t.jpg" width="100" /></a>
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With help from my friend Carl I managed to get the glove box bracket off, which was blocking the heater control cables. I had given up breaking the screw loose and was setting up to drill when Carl happened by. He tried a left-handed drill bit (Snap-On) but it would not bite enough. Next he tried an easy out, but that would not hold. Finally we ended up drilling off the head.<br />
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With the support bracket out of the way I could get the RH side of the heater free, but the LH side refused to drop down. Eventually I realized that I had never disconnected the heater hoses. I loosened the clamps with a 6mm socket but the hoses refused to budge, so cut them off. One more thing to deal with in the future.<br />
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I had ten minutes left, but I decided to call it a day.<br />
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Not sure I want to bother putting the heater back in, because in Honolulu it is never used. But the heater is also the fresh air vent system, and without it the interior will be even stuffier than it is, especially in the rain. Maybe I can work out a simple substitute.<br />
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posted from <a href="https://market.android.com/details?id=pl.przemelek.android.blogger">Bloggeroid</a></div>
</div>Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0tag:blogger.com,1999:blog-5831132788099973832.post-70928948207510963012012-01-28T20:58:00.001-10:002012-02-04T22:27:52.313-10:00Heater almost out, door skins ordered<div xmlns="http://www.w3.org/1999/xhtml">
<a href="http://www.flickr.com/photos/garydunn808/6821528463/" title="BMW120128-01 by garydunn808, on Flickr"><img alt="BMW120128-01" height="75" src="http://farm8.staticflickr.com/7146/6821528463_d0c624a922_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6821528467/" title="BMW120128-02 by garydunn808, on Flickr"><img alt="BMW120128-02" height="75" src="http://farm8.staticflickr.com/7019/6821528467_cae1271546_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6821528471/" title="BMW120128-03 by garydunn808, on Flickr"><img alt="BMW120128-03" height="75" src="http://farm8.staticflickr.com/7156/6821528471_73741c8f08_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6821528477/" title="BMW120128-04 by garydunn808, on Flickr"><img alt="BMW120128-04" height="75" src="http://farm8.staticflickr.com/7152/6821528477_55279a6bb6_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6821528479/" title="BMW120128-05 by garydunn808, on Flickr"><img alt="BMW120128-05" height="75" src="http://farm8.staticflickr.com/7014/6821528479_0c5812cb1a_t.jpg" width="100" /></a>
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I went back to removing the heater. Removed the plastic flex tubing, one clamp each side (one end not clamped). Disconnected the wires from the brake light switch. Removed the fan motor, which does not turn. Removed the four 10mm nuts that should have released the heater. Had to tap with hammer and pry with screwdriver, finally came free. But not out. <br />
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Some of the heater control cables run over the bar that sports the glove box. The bar is attached with brackets, with two Phillips head screws on the outboard end. One screw is frozen. It does not look rusted, so the problem is probably whatever it is screwed into. Even an impact tool would not budge it. Shot it with PB Blaster and called it a day.<br />
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Last week I sent some money to England for new door skins. Shipping what it is these says I'll be lucky if they arrive by spring.<br />
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The Lotus is going to need a new water pump. A big job on that motor. I would like to have the doors fixed on the E9 before I push it outside to make room for the Lotus this summer.<br />
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posted from <a href="https://market.android.com/details?id=pl.przemelek.android.blogger">Bloggeroid</a></div>
</div>Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0tag:blogger.com,1999:blog-5831132788099973832.post-72302615932488721932012-01-21T17:30:00.000-10:002012-01-23T12:43:27.614-10:00Lotus at BCCH tech day, hard starting diagnosedI volunteered my Lotus for the January BCCH tech session. We met at the Boys Club on the 21st, which was perfect for me because Patrick works on his cars there. Patrick has just restored a Jag, but he also has three Europas under restoration. (See, I'm not so crazy!)<br />
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My main issue was the hard starting. Ever since I put the car back on the road it has been hard to start. When I turn the key the starter makes a lot of noise, but it is reluctant to catch.<br />
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My original cure was to replace the original starter with a geared down <a href="http://www.densoaftermarket.com/">Denso</a>, specially prepared for the Twin Cam. I got mine from <a href="http://davebean.com/">Dave Bean</a>. Still had the catch problem, but it cranked with a lot more authority.<br />
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Every once in a while I noticed another thing. The starter would not turn the engine over at all. The only sign of action was the pitch coming from the Holly fuel pump dropped a bit. Wait a bit and it would be back to normal.<br />
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<a href="http://www.flickr.com/photos/garydunn808/6746620415/" title="BMW120121-01 by garydunn808, on Flickr"><img alt="BMW120121-01" height="75" src="http://farm8.staticflickr.com/7033/6746620415_c6d153e723_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6746620417/" title="BMW120121-02 by garydunn808, on Flickr"><img alt="BMW120121-02" height="75" src="http://farm8.staticflickr.com/7004/6746620417_51a491a28b_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6746620421/" title="BMW120121-03 by garydunn808, on Flickr"><img alt="BMW120121-03" height="75" src="http://farm8.staticflickr.com/7035/6746620421_19c129ffae_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6746620433/" title="BMW120121-04 by garydunn808, on Flickr"><img alt="BMW120121-04" height="75" src="http://farm8.staticflickr.com/7164/6746620433_76d3c3fdbc_t.jpg" width="100" /></a>
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All this time I thought I had a bad ground or a faulty relay. Saturday's session revealed two things. First, the starter is being cooked by the exhaust pipe that runs directly under it, which causes it to stick. Once it cools, it comes back to life. I wrapped the starter in a heat shield for just this reason, but to do it right I need to fabricate one out of aluminum. Second, the teeth on the flywheel ring gear are hammered flat, making it difficult for the pinion to engage. The rattling sound is the pinion bouncing back and forth.<br />
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At this point I need to mention that lately the engine has been making a noise that sounds like a failing water pump. Could be the timing chain tensioner, but the water pump is much more likely. To fix that I will need to pull the engine and transmission, remove the head and oil pan. (Did that back around 1979, just before the car went into the barn.) Time to restore the engine color back to the proper grey. New clutch and throw-out bearing. New timing chain. Install the new coolant pipes I bought a few years back. There goes my summer.<br />
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I want to thank all the guys from BCCH who participated in chasing after this daemon. Special thanks to Patrick, a wealth of knowledge. Good pizza, too.<br />
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<br />Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0tag:blogger.com,1999:blog-5831132788099973832.post-9892168698914352072012-01-14T18:14:00.000-10:002012-01-22T18:16:14.653-10:00Heater blower, part 1I started on deconstructing the dash and glove box area in order to safely repair the rust-throughs at the rear of the engine compartment. Having gotten this far I decided I should extend my reach by removing the hard plastic coating in that location (same stuff as on the floor?) and to the rust breaking out around the blower motor mount.<br />
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<a href="http://www.flickr.com/photos/garydunn808/6740118561/" title="BMW120114-01 by garydunn808, on Flickr"><img alt="BMW120114-01" height="75" src="http://farm8.staticflickr.com/7141/6740118561_af4c05e8c6_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6740118569/" title="BMW120114-02 by garydunn808, on Flickr"><img alt="BMW120114-02" height="75" src="http://farm8.staticflickr.com/7164/6740118569_f6a4852eac_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6740118573/" title="BMW120114-03 by garydunn808, on Flickr"><img alt="BMW120114-03" height="75" src="http://farm8.staticflickr.com/7034/6740118573_e3d0cd8d6f_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6740118583/" title="BMW120114-04 by garydunn808, on Flickr"><img alt="BMW120114-04" height="75" src="http://farm8.staticflickr.com/7160/6740118583_309220892a_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6740118591/" title="BMW120114-05 by garydunn808, on Flickr"><img alt="BMW120114-05" height="75" src="http://farm8.staticflickr.com/7141/6740118591_9e9e393767_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6740118595/" title="BMW120114-06 by garydunn808, on Flickr"><img alt="BMW120114-06" height="75" src="http://farm8.staticflickr.com/7003/6740118595_7911fb65f4_t.jpg" width="100" /></a>
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According to the manual, removing the blower requires removing the blower duct under the dash, and to do that requires removing some of the controls. Unfortunately the manual was not entirely clear as to what gets removed.<br />
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<a href="http://www.flickr.com/photos/garydunn808/6740122407/" title="BMW120114-07 by garydunn808, on Flickr"><img alt="BMW120114-07" height="75" src="http://farm8.staticflickr.com/7142/6740122407_210f623882_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6740122413/" title="BMW120114-08 by garydunn808, on Flickr"><img alt="BMW120114-08" height="75" src="http://farm8.staticflickr.com/7168/6740122413_065e386ffb_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6740122419/" title="BMW120114-09 by garydunn808, on Flickr"><img alt="BMW120114-09" height="75" src="http://farm8.staticflickr.com/7016/6740122419_18f3283c53_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6740122427/" title="BMW120114-11 by garydunn808, on Flickr"><img alt="BMW120114-11" height="75" src="http://farm8.staticflickr.com/7021/6740122427_5c8370272d_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6740122429/" title="BMW120114-12 by garydunn808, on Flickr"><img alt="BMW120114-12" height="75" src="http://farm8.staticflickr.com/7153/6740122429_600bd1b934_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6740126421/" title="BMW120114-13 by garydunn808, on Flickr"><img alt="BMW120114-13" height="75" src="http://farm8.staticflickr.com/7034/6740126421_944eb304cc_t.jpg" width="100" /></a>
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<a href="http://www.flickr.com/photos/garydunn808/6740126429/" title="BMW120114-15 by garydunn808, on Flickr"><img alt="BMW120114-15" height="75" src="http://farm8.staticflickr.com/7142/6740126429_7315075f1b_t.jpg" width="100" /></a><br />
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<a href="http://www.flickr.com/photos/garydunn808/6740126447/" title="BMW120114-17 by garydunn808, on Flickr"><img alt="BMW120114-17" height="75" src="http://farm8.staticflickr.com/7020/6740126447_8ec19e01cc_t.jpg" width="100" /></a>
<a href="http://www.flickr.com/photos/garydunn808/6740126461/" title="BMW120114-18 by garydunn808, on Flickr"><img alt="BMW120114-18" height="75" src="http://farm8.staticflickr.com/7171/6740126461_eb887941fe_t.jpg" width="100" /></a>
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The control panel was attached to brackets on each side with a single bolt, head facing outboard. I thought I needed to disconnect the control cables, and did disconnect one, but in the end I left the assembly in the car. The blower duct was coming apart at the upper seam on the LH side. Looks like it can be glued.<br />
<br />Gary Dunnhttp://www.blogger.com/profile/17931060013985114416noreply@blogger.com0