72' Fjord CSI resto

Wladek

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Update time!
So, due i wasn't fully satisfied with results of the first flushing block cooling system flushing, i made second flush with phosphoric acid, this time block was soaking for ca. 48hours & after final water flushing, i can tell you that results where really great!
So then:
1. I flatten all cast iron burrs for better cooling fluid flow (water pump mount).
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Flatten all burrs in oil channels
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2. Cylinders rehoned
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3. Engine block caps replaced
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Some new engine hardware
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And then, when i thought that block is fully cleaned, shiny, sharp edges inside & good to go with reassembly i decided to unscrew that big m34 cooling compartment screw, that is on the front wall near timing chain. And what i found there??? - NEXT WALL!!! And that after 48hours of soaking in acid!!!
It's view of first culinder wall.
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Hammer & flat screwdriver didn't helped a lot, so i used 3Joule pneumatic hammer.
And it wasn't easy even for that machine!
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After that i pulled out couple bigger peaces of something as below that is hard as rock. I think it was there even the day when car was leaving BMW factory, remains of casting molds.
Second side that is unvisible - was a little bit better, but not too much.
Before this job - i think cooling fluid flow in that part of block for one half of first cylinder was fully closed/blind.
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Obstructed
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Wladek

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New bearing in crankshaft
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New sprocket
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Crankshaft was nominal, but i made all needed measurements any way.
Main ca. 60mm (59,95-59,98mm)
Conrod ca. 48mm (47,97-47,99mm)
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New bearings:
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Main crank plastigauge measurements - all in specs, actual clearance is ca. 0,0017-0,002" (ca. 0,04-0,05mm). Book specs are ca. 0,002-0,003"
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Reassembly:
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And with final torquing - all f.cked up. One of the bolts cracked with 55nm of torque.
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Luckily i was able to pulled out the cracked part, without any additional damages.
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Wladek

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Some lighter work
Windows gears cleaning & regreasing:
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Finally assembled & tested
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During zinc plating - they lost one of my heater box flap shafts, so i decided to fabricate 2x stainless instead of regular zinc plated.
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Reassembled headlights wipers, after re-zinc plating & before painting.
Couple custom made rivets where needed, & all is good now.
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Made "mirror-effect" powder coating of taillights reflection plates.
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I liked the idea of Rob @teahead to leave brake calipers in yellow zinc-plated colour, so i just clear powder coat the calipers:
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And finally re-assembled them:
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Some zinc plating
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Wladek

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Thanks Steve:)
Yes, patience is critical if you want to make all things proper way, sometimes i am lack of patience & need a little brake to calm down. Usually at this point, i start to make wholy different things to relieve the head.
The main problem with E9 parts, is that first impression about their condition - really doesn't matter. So many times i had parts that looked so well & in the end after blasting or plating they showed up a new not very attractive face; from other side i also had a lot of parts that looked not very promising, but in fact became very good cores.

p.s. when i have internal resistance or just don't want to do something with e9, i always repeat to myself "it won't do itself, it won't do itself" after 5x or more times of repeating, i am usually good to go futher.
 

paul

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Hi Wladek...........I am curious....do you own shares in Zn plating company or do you just love Zn plating as a hobby :D looks great and I agree with your comment
"as i am making ultimate 70's car - why not improve the factory solution" I have taken the same attitude with my car. Actually I painted the air blower cover and the headlight access panels Turkis rather than black . Do you like the rear badge?
 

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Wladek

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do you own shares in Zn plating company or do you just love Zn plating as a hobby :D
No, i do not own shares, this company owners are bunch of assholes. Every single time i give them new orders - they charge me more & more; in near future Zn plating will cost me more like Gold plating; :)
Every single part that i received with my e9 from previous owner was so ugly, dirt & greasy, i was sort of disgusted because of that, so i decided that after my TLC this parts in their new life with me will be nice & shiny, so i just do my best.
Actually I painted the air blower cover and the headlight access panels Turkis rather than black . Do you like the rear badge?
I love your car, you made wonderful job with it, i wish mine in future was as good as your's.
To be true - not many e9 restorations really impressed me, but yours is wholy different story, body work/paint job work was just amazing.

Due blower under that cover is black, i personally prefer black cover, so was sort of harmony between these two parts, but that doesn't mean, that turkis cover look bad, it also look nice.
Badge is cool - 3.5 under the hood - 3.5 on the boot, all match as it should.;)
 

Wladek

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Some powder coating was made this week
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Reassembled my wipers mechanism
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Couple weeks back piston rings gaps adjusting was made, so was all in specs, all rings where grinded, measure couple times etc. etc.
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This week received package from BMW with new main bearings bolts, washers etc., so was able to continue the work with engine block.
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Main bearings where tightened (bearings gaps where checked above), so after final troque 60Nm i was able to check side play of cranckshaft - total was ca. 0,05mm (each side ca. 0,025mm)
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All pistons where fully cleaned, all carbon deposits where removed, also from all gaps & then sligthly manually polished with metal polishing compound, so dirt does not stick to them so well in future.
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New piston rings on:
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Each ring gap was set ca. 120 degree to other, so oil leaks where minimal
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Connecting rods torque 55Nm
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All six conrod bearings gaps where ca. 0,025mm
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And done - pistons seat right.
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Wladek

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Thank you Guys for nice words, i appreciat it;) I wish i was a little bit closer to final work, but it's still long, long way to go.
 

Gazz

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i wish you alot of courage to assemble all this again :D
I hope you have a very good memory and/ or an extensive knowledge of E9s. Mine was totally disassembled when I bought it as a given up on project. It was only this forum, the blue manuals ( useless at times ), and having another E9 as a template that enabled me to get anywhere, as a novice.

I presume some of those plated parts will be painted?
 

Wladek

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I hope you have a very good memory and/ or an extensive knowledge of E9s.
As for now i think i remember most things, but will see if i will still remember all this when the car will be back in assembly.
I presume some of those plated parts will be painted?
All parts that where originally black or other colour - will be black or other colour & almost all that where originally bare Zn plated - will be bare Zn plated. I want to go stock colours.
 
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