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Old 08-20-2010, 04:17 PM   #1
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Default My '75 2002 M20 Sleeper

~So my flickr account is being retarded. Bear with me while I figure out what the f it's doing. Thanks~


For the past couple of years I've been working towards/dreaming about picking up a 2002 to call my own, and a couple of weeks ago I finally pulled the trigger. I went up to Detroit and amidst a strong fuel/exhaust smell she managed to tackle the 4 hour drive back to Springfield (Ohio) without a fuss so I can't complain. Anyway, without further ado here she is:




The engine runs pretty strong, not that I have much to compare it to.

http://www.flickr.com/photos/28523131@N07/4879305278/



Once I got it home and really started looking it over, I found out that she has a few nice surprises and a few not so nice surprises. But that's all to be expected I suppose.


First, a 32/36 w/ manual choke:

http://www.flickr.com/photos/28523131@N07/4879305304/


Next, a Tii Mechanical Advance Dizzy:

http://www.flickr.com/photos/28523131@N07/4904431570/

Then I forgot to take a picture, but a full Ansa Sport Midsection and Muffler, which is pretty freaking loud @4000 rpm cruising down the highway lol. I think there's also a leak somewhere though, so that's definitely not helping anything.

The interior also came with a 3 gauge pod with oil pressure, voltage and an old school vdo clock (that still keeps time!) as well as a very old tape deck lol.



Now some of the not as nice things:

Driver side rocker panel

http://www.flickr.com/photos/28523131@N07/4903991947/


Driver Side Floor with carpet and sound deadening removed:

http://www.flickr.com/photos/28523131@N07/4903991969/


Oil leak from somewhere around the oil filter housing / intake manifold / head gasket.

http://www.flickr.com/photos/28523131@N07/4904195927/



So the plan is to fix the rusty area's and get the interior back to being sealed from the exterior. I've got some plans to help stiffen her up where it counts that shouldn't add to much weight either. In the end it won't be a show car by any means, more just a car meant to be driven. I've already started some of the rocker work so I'll post up more pictures soon.
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Old 08-20-2010, 04:32 PM   #2
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awesome. id love to own an old '02. any plans for the motor? s14b25 swap??
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Old 08-20-2010, 04:36 PM   #3
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Quote:
Originally Posted by KidneyBoy View Post
awesome. id love to own an old '02. any plans for the motor? s14b25 swap??
although awesome, I would much prefer seeing an F20C1 swap
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Old 08-20-2010, 04:49 PM   #4
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For right now I'd probably just hot rod the M10. Their basically bullet proof except for the rockers and springs, which can be replaced with much better pieces for not a lot of money. You could easily get aggressive cams, dual webers, headers, rockers, valve springs and valves for under $2000. An s14 swap would start at around $7500 for everything you need, which is more than 4 times what I payed for the car lol.
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Old 08-20-2010, 05:08 PM   #5
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those m10s are good little motors but theres a lot to be desired when it comes to power... your could always run MS and turbo the little guy.
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Old 08-20-2010, 05:57 PM   #6
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Yup, it's in the back of my mind. for now I'm pretty much focused on getting the rust under control and refreshing the suspension and interior. Then I can worry about the go fast goodies lol
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Old 08-20-2010, 10:10 PM   #7
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Rust scares me.
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Old 01-25-2011, 02:14 AM   #8
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Sorry for the lack of updates, better late than never. I got really crunched for time at the end of the summer and then I thought I lost all of the pictures of the end of the rust repair, but I recently found them on an old hard drive so all is good now. When we last left off the driver side was finished, and just needed the welds ground down and cleaned up.

What started as this:




Now looked like this:




Muuuch better. (As much as my feet loved the open air feeling). So now the next step was the passenger side repairs, which was by far the worst rust damage on the car. I could go into details about the ****ty patch job some previous owner did on the passenger floor, or the holes in the rear rocker panel, but I think I'll just let the pictures do the talking.

The Passenger Floor. Maybe there's at least some hope of clean metal underneath....




No Such Luck:




Finally cut it back to some 'clean' metal:




Then new floors were cut out, beads were rolled, and then welded in like the drivers side. Which I forgot to take pictures of.

Next was the rear passenger fender area. This is were you could really start to tell the car spend a lot of winters in Michigan (and were the wind noise was coming from on the drive home).

Lots of cancer:




View from the inside, cause even backseat drivers need a sunroof for their feet.




Luckily the cancer could be cut away:




It did get fairly deep though...




So after cutting out that rust and welding in some new metal I gave it a nice coat of POR-15:



After Drying:




And then a new panel to cover up the insides from more damage:

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Old 01-25-2011, 02:16 AM   #9
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Then I needed to make a new outer fender panel. Here it is in the earlier stages of being hammered out:




And here it is welded in place. It's not the prettiest but I'd say it's pretty darn close for my first hand-made fender.




Now with the majority of the rust repair done (woo!) it was time to help makes sure things didn't start to rot away again. but before you can really protect the metal, you have to get down to the bare stuff. This meant getting all of the old, tar-ish sound deadening off of the floors. Normally this is a terrible job that can take days with a heat gun and a scraper. Unless you know a little trick. Say hello to my little friend...

Dry ice in a convenient pillow case:




It may look tame, but it's doing it's thing. After 5-10 minutes under the pillow case, the sound deadening chips right off like a Maaco paint job.




Here's the rear with all the sound deadening off the floors. They are now ready to be covered in POR-15:




But first let's give a nice test fit to those e24 rear seats. After some trimming of the rear fiberglass they fit like a glove.




With the rest of the interior sorted and repaired, the floors got coated in POR-15 top and bottom (where the undercoating had come off):






Then as the POR-15 was drying, I prepared the next layer to go down. Sound deadening tar paper and Insulating ducting foam. Much like Dynamat and carpet insulation in function, but a whole lot cheaper. If I ever get to the point of doing a 'frame off' restoration, then I may splurge on the name brand stuff. Until then these will definitely do just fine.





Laying down the Tar Paper:



Laying down the insulation on top of that:






With all that done there was just a couple of minor details to button up like re-sealing the gas tank and patching some holes in the trunk. Then the new fuel lines were run and hooked up to the engine. Finally after a couple of cranks she fired up as good as ever. That was about as far as I managed to get before school started and I was back up on campus. I did drive it up at school on and off for a couple of months until the weather really started getting cold. At that point, the lack of a working heater/defroster meant that the windows would fog up within the first 15 seconds of driving. So she got parked until I could find more time to work on the heater box and brakes. Thankfully that time came at the beginning of the new year. hopefully I'll be able to upload those pics in the near future.
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Mica - 2000 BMW 323i - The one that started it all
Fiona - 1975 BMW 2002 - The Definition of Project Creep
Heidi - 1988 BMW M5 - The piece of BMW history
Silvia - 2013 Subaru WRX - Stock, for now

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Old 01-25-2011, 03:56 AM   #10
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Looking good man thats awesome how close the color is to the e46.
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Old 01-25-2011, 07:55 AM   #11
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Thats awesome!
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Old 01-25-2011, 08:01 AM   #12
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Looks good man. Someday I wish to undertake such a challenge.
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Old 01-25-2011, 08:11 AM   #13
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very cool! nice work
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Old 01-25-2011, 08:46 AM   #14
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Good work so far. I like old car restorations.
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Old 01-25-2011, 09:38 AM   #15
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really great work. I've always wanted a 2002, but I would have been completely inept at trying to fix that much rust damage.
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Old 01-25-2011, 09:41 AM   #16
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Subscribed! Awesome work. I would LOVE to take part in something like this someday. If you ever need a hand, I would be happy to help.

BTW, here is another product too that I have seen before. Not sure if the price is the same, but thought I would throw it out there.

http://www.magnetpaints.com/underbody.asp

Good luck with the rest of the build
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Old 01-25-2011, 09:43 AM   #17
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WOW I LOVE THIS CAR!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!
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Old 01-25-2011, 10:38 AM   #18
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sweet job dude!
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Old 01-25-2011, 11:09 AM   #19
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Very nice documentation! A lot of work.

I had a 74 2002 in the late seventies and I think it was already starting to have rust issues when I got rid of it in the early eighties. Rust was becoming evident behind the front turn signals and on the front fender down low in front of the door. I also had to replace the gas tank at some point because it started having pin holes all over. You don't show pics of the rear shock towers but I think that's one of the common places for rust I assume yours are all right. Compared to Japanese cars of the day the 2002 was way ahead in terms of driving dynamics, Japanese cars were crude in comparison. They rusted too, you don't see many Jap cars from that era today.

Nice work.
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Old 01-25-2011, 11:21 AM   #20
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Beautiful 2002. A roundie is on my short list. I love, love the m10.
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