Restoration of a 1984 280i "Barn Find" - Part 4
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February 26, 2008:
In my latest update, I’ll fill you in on what’s been going on since my last news in September 2007. Although progress throughout this project has been slower than I would have liked, we have also encountered some headaches we may not have expected.
For example, in redoing the front suspension, some of the suspension members on the left
side had been welded together….that’s right, WELDED!. This was just another example to show that previous, shall we say, “jackleg mechanics” had worked on this car and had done very little that was right. So, my trusty mechanic T.J. carefully broke the welds, cleaned up the various components and then reassembled things the way they should have been. In the process of doing the suspension, all new bushings were installed, the brake calipers were completely rebuilt and new AVO dual adjustable shocks and new springs were fitted.
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When he got to the rear suspension, he removed the entire unit from the car. Here the rear brake calipers also had to be rebuilt, new pads were fitted, and new rear discs were also installed as the ones on the car didn’t have much life left. Also, we found that the nut on the left rear stub axle was held in with a large cotter pin that had been fitted through a hole that was drilled into the threads of the stub axle to hold everything in place. The reason for this became apparent by the tell-tale flat place on the bottom of the hub carrier on the left side. Apparently, the left rear wheel parted company with the car at some point in the past resulting in the ‘careful grinding down’ of the bottom side of this component. The shop carefully reworked the threading on the stub axle and fitted a new nut with confidence I would not suffer the same malady as had previously occurred.
Then, when it was time to fit the shocks and springs on the rear, the right side went in just fine. But, the left side posed a problem when the remaining AVO shock did not match the one installed on the other side. So, I contacted my supplier in the UK, sent them photos of the problem with the shock, and soon a replacement shock was in hand and installed. All of the rear suspension was also carefully detailed before reassembly, making the area look very tidy indeed.
While in the rear of the car, all the hoses around the fuel tanks, to the fuel pump, etc were replaced and new bushings were fitted throughout on the suspension. And, we had previously shipped the alloy wheels off to be refinished. Previously painted with white centers, the wheels were stripped and completely refinished with silver-grey centers and polished rims and then clear coated for protection. They look fabulous now with the new tires mounted. Also a full set of new chrome lug nuts rounded off the package.
T.J. was also busy working on the electrical wiring inside the car. It was a mess to start with but with perseverence, he got both windows working fine, cleaned up the wiring behind the console and made sure all the switches were working, installed a new AM-FM, CD unit and power antenna, etc.
Then, it was time for the hydraulics. The clutch master cylinder was fitted along with a new slave cylinder. Then the brakes posed the problem. Once everything had been rebuilt, the brake master cylinder was leaking. So a rebuild kit was called for there.
He also went to work replacing all the hoses in the engine bay with silicone hosing, and installing the intake manifold and plenum chamber that were stripped and powdercoated. However, he then found out that the throttle body was damaged and needed replacement. Fortunately, I was able to source a nice used one and that was being installed. The rebuilt radiator has also been installed and he’s working on the remaining components to get the car driveable, at long last.
Next, the new windshield will be installed and a new exhaust system will be fitted to replace the rotten excuse for an exhaust that was on the car. Providing we don’t run into any more “surprises” I hope to have the car roadworthy by about the first of March. Then it’s time to have the upholstery shop do its magic with two new leather hydes, after which it’ll be time to have the front and rear fiberglass bumpers fitted and painted, along with the 350i front spoiler and the rear valance. After that, some final heavy duty cleaning and detailing will commence to get the car ready for its first outing, hopefully in mid April.
Stay tuned, the light is visible at the end of the tunnel.
- Marshall Moore
