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2002 Dark Silver MCS - One for life

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Top work. I like the A pillars [emoji1303] Replacing my lads pillars with black one's and will be retrimming headling black too. How much did the hydro dipping cost? My lad had been thinking of doing the same



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I bought them already done for £30.00



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Bargain at that price. Are you looking out for the other pillars?



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Bargain at that price. Are you looking out for the other pillars?



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Not at the moment?



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Eventually after close to 10 years of ownership I have replaced the front drivers side speaker.


Unfortunately it never stops there, well the door card was off.


bf65abcab6f2510199c40ce6c23f1636.jpg201708 ... 3f1636.jpg"><a href=https://uploads.tapatalk-cdn.com/20170806/bf65abcab6f2510199c40ce6c23f1636.jpg' alt='URL>'>


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Now in body colour, passenger side to do next.


Door stay has had the rust removed and paint applied, and some sound installation placed on the inside of the door.


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Installed speedo and tachometer polished aluminium covers


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Got the passenger door trim repainted in body colour.


I thought I'd have a go at replacing the front wheel bearings and my favourite element of my car (rust) unfortunately has extended the time frame, so not wishing to do half a job I have started trying to eradicate the rust.


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Bolts holding the existing bearing in would not move so ended up having to remove the hub.


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Soaking in a bucket of bilthammer deox C, never used this before and makes things so much simpler.


Repainted and assembled ready to put back in once I sort out all the other rust.5aacc4352e8be8b85d7c9df019a99264.jpg201710 ... a99264.jpg"><a href=https://uploads.tapatalk-cdn.com/20171001/5aacc4352e8be8b85d7c9df019a99264.jpg' alt='URL>'>

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Sorted out the brake calliper carrier whilst I was in there

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Random image before I started all this

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Current status


Brake calliper carrier repainted

e73a0b52c76cb08340554386fa843747.jpg201710 ... 843747.jpg"><a href=https://uploads.tapatalk-cdn.com/20171001/e73a0b52c76cb08340554386fa843747.jpg' alt='URL>'>


Strut area and arch repainted as the hub needed removing the coil over was taken out also.


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Wishbone soaking with the brake disc getting a quick dip in the rust removal solution.

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The parts left behind to clean up and paint (awaiting another delivery)

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That bilthammer deox C seems pretty potent ! Seems like it does the job :D

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Removed the wishbone from the magical rust remover bath, gave it a quick going over with a wire brush attachment in the drill, very good results from where I started. Then applied zinc primer and 3 top coats.

327984ee70faa8f6d699b41bc9670339.jpg201710 ... 670339.jpg"><a href=https://uploads.tapatalk-cdn.com/20171007/327984ee70faa8f6d699b41bc9670339.jpg' alt='URL>'>

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The deox c gel has worked well enough on the brake calliper, which has also been given another dusting of paint.

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The hub assembly is now complete after receiving a new brake disc backing plate.

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I've got the drop link soaking in a new bath of deox c and the drive shaft has had a second coat of the gel.

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That bilthammer deox C seems pretty potent ! Seems like it does the job :D

 

It is and saving me money on shot blasting



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Removed the brake disc from the deox c water bath and it looks like new.

bae0289e4ecff37924fd9171fdce9956.jpg201710 ... ce9956.jpg"><a href=https://uploads.tapatalk-cdn.com/20171004/bae0289e4ecff37924fd9171fdce9956.jpg' alt='URL>'>


So as I had planned to replace the rear pads I dropped the rear disc in there to.

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The ABS sensor would not come out of front hub it was rusted in solid and I ended up breaking it, so I had to purchase a new one.


Sensor hole completely cleaned up with the sensor installed and all bolts torqued correctly.

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I have purchased some bilthammer deox c gel to coat parts I did not want to remove at this time.


Driveshaft before and after with the gel coat

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Brake calliper piston

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Coilover cleaned up with a quick touch up of the top mount

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Out of sequence unfortunately



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It’s gonna be like a new car soon. I take it the rust killer does not affect the seals on the brakes or anything ?

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All back together now, waiting to get the wheel installed.


All bodywork painted areas were coated in bilthammer cavity wax


I ended up replacing with new the following.


Inner ball joint

Outer ball joint

All associated nuts and bolts

Brake disc backing plate

Wheel bearing

ABS sensor


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I eventually replaced the bonnet release cable, I now have a bonnet that opens on both sides without having to go in under the wheel arch.


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I also had a go at restoring the original wheel bearing.


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Now sat in the parts box covered in oil



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Started on the driver's side restoration, impatience and the need to do something to keep the mind clear. This is what I am faced with.


78dc443eb59c4b8c2cd8fe8edd0d7650.jpg201711 ... 0d7650.jpg"><a href=https://uploads.tapatalk-cdn.com/20171111/78dc443eb59c4b8c2cd8fe8edd0d7650.jpg' alt='URL>'>


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Having the correct tools and practice had made the dis-assembly of this side easier, but of course not without it's issues one still unresolved, awaiting a grinding cutting disc delivery.


I again had to remove the hub assembly as a complete unit. Do we all just love rust........


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A pile of rusty parts to sort out or replace, parts and paint ordering has commenced again.


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The outer ball joint could not be removed, rounded nut and lots of rust, the pickle fork could not remove it, eventually after cutting the nut off a very large hammer hit many times released it, hit away from you and in the direction of nothing of value, it took down a number of my Lin bins on the walls.


Currently soaking the drive shaft and brake line bracket in deox c gel.


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This is currently being very stubborn, access is limited as I am not removing the drive shaft. The bolt rounded and even my Irwin bolt extractors are also failing, next step is to cut the ball joint bracket off and see how that goes.


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Drivers side Components going through extensive rust removal


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Wheel bearing hub before during and after


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Wishbone before during and after


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Box of new components waiting to be assembled and installed


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Drivers side Components going through extensive rust removal


e811ca5513659b3160fb7d0af9a5e9f8.jpg201712 ... a5e9f8.jpg"><a href=https://uploads.tapatalk-cdn.com/20171216/e811ca5513659b3160fb7d0af9a5e9f8.jpg' alt='URL>'>


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Wheel bearing hub before during and after


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Wishbone before during and after


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Box of new components waiting to be assembled and installed


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Good to see more progress. I think of this when I start playing around with mine, and while I cannot get anywhere near the quality you are, it still amazes me the detail you put in. [emoji2]



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The difficultly in removing the inner ball joint continued and eventually was removed with 1500mm breaker bar (old curtain pole), not before I slipped with a pry bar and split the inner CV Rubber boot. So I had to remove the driveshaft which I was not planning to do which created much greater access to the seized bolt.


£42 later from BMW I had a new rubber boot and clips. Whilst out I thought I would refurbish the drive shaft.


Initial plan was to improve insitu, deox C gel cleaned it up.


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Once off the car I could strip it down, circlip removed, tripod bearing gently tapped off, remaining rubber boot removed, 16 year old grease cleaned away, lots of emery cloth on the shaft followed by deox c gel to enable painting and re-assembly with new parts.


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All parts are now refurbished and ready to be reinstalled, I just need to do some scrubbing of the wheel arch and a little bit of surface rust removal before painting and then I get get it all back together and off the axle stands.



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Great thread this :)

 

It’s like a better Haynes manual [emoji2]



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Not much visible progress lately, though I have been attempting to get it ready for re-assembly. All the surface rust which was minimal was ground back to bare metal, treated with deox-c, zinc primed, seam sealed, stone chipped and then a top coat, all for preservation purposes. It was the healthiest corner of the car with minimal surface rust mainly on the spot welds. I then applied where needed some clear cavity wax.


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With a new inner ball joint installed

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I am currently struggling to get the tie rod end removed (16 years of activity) it is on day two of soaking in plus gas.


I have all newly restored or brand new components ready to install with new bolts and fixings.



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Eventually the driver's side is now all re-assembled


Ended up replacing the following with new


Inner ball joint

Outer ball joint

Track rod end

Wheel bearing

Inner cv rubber boot

Brake disc plate

ABS sensor

Every bolt


During the re-assembly process


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All back together


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Life's been busy this year I've been moving things along slowly.

The front tyres were getting towards the legal limit, and had been like that for some time with no change due to the lack of mileage. Two new Toyo T1R Proxies were installed. Sometime ago I also foolishly damaged one of my wheels on a kerb, I bought a replacement at the time and the damaged one sat covered up  in my workshop area, the wheel specialist did a good job repairing it and I now have a perfect spare wheel.

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A number of years ago some nob head in a car park damaged my driver's side Rear arches, I did a quick repair job and forgot about them, although not perfect I have now repainted them both.

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Whilst I had the rattle cans out I also repainted the front passenger side arch as I had chipped the paint during my inner arch restoration "slipping on a seized nut with a breaker bar"

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Whilst installing the newly painted item I noticed that the a panel arch was not seated correctly one of the moulded clip holders was broken, I made a template from thin plywood, and using the plastic top of a CD storage case I made a replacement and bonded onto the arch left it for 48 hours and then reinstalled.

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I was lucky enough to purchase some time ago a v monitor for a very reasonable price which I have now installed in the useless space underneath the steering wheel.

Although currently on the floor due to ongoing work.

I recently purchased at a remarkably low priced GTT oil catch can which I bought as a spare, I have now completely refurbished it.

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........................in a malt vinegar dip
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Whilst working on the interior I damaged beyond repair my first ever addition to my car an iPod cable which got caught in a seat runner.

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Getting a replacement was a little more difficult than I first imagined although gave me a chance to take apart something I haven't before.

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To help to complete my interior I have had the cup holder moulded section carbon hydro dipped (by Vital Hydro graphics in Staffordshire)

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Whilst taken apart, new anti squeak tape was installed every where.

Current carbon parts waiting to go back on the car (waiting for the blue plastic nuts to arrive before I put it all back together).

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This part is currently being dipped.

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I have the seat backs off ready to be sent away to be carbon dipped.

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Cold air intake......simple monitor installled???????

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The following items I hope will be corrected over the next 12 months.

The minor surface rust on the floor pan will be removed on the underside and protected with zinc primer, stone chip and then top coat.

I hope to be able to attempt to remove the front sub frame and have it shot blasted, treated with bilthammer rust removal and convertor, then zinc primed and painted with Por15, with all new fixings installed.

I have a new fuel filter to install

Currently waiting for delivery of a matching Recaro rear seat bench which I have just purchased off eBay.

The current mileage which is likely to remain relatively unchanged over the next 12 months.

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Last item I replaced the tatty build date sticker.....it's starting to age.

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Edited by RT2002MCS
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