Gary's Avus Blau 3.0CS rebuild

m5bb

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Here's a problem I encountered that some others may find as well.
The crappy plastic fender grills.
When removed 3 years ago, the posts break off. BMW uses a rubber donut shapped washer that pushes on the post that goes through the metal fender and that holds the grill on the car.
So 2 relatively new grills were trash.
I thought about this and remembered my model train days when I would buy brass tubing from the hobby store. I had some around and was lucky I had the correct size to push on the posts and make them long enough to have some post on the inside of the fender to attach the rubber washers to. NOT, the BMW rubber washers have a spring steel disk inside them with the one-way teeth.
Push it on and it ain't coming off. That's why the posts break. I tried to drill the metal disk hole to a bigger size but the spring steel does not drill easily and the one way teeth catch on the drill bit and then it tares out of the rubber washer.
So once I got the brass rod on there, it was how was I going to hold them on. How about a washer and a tiny rubber o-ring. It took a good deal of effort to get this o-ring on the post so I am pretty confident it will stay. I will monitor after some miles.
I thought about putting threaded rod in the grills but was afraid they would break.
So here's a couple photos to explain this too complicated explanation. As a career photographer a photo is worth a 1000 words. Enough said.
 

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m5bb

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Wiring details.
All waterproof connectors.
Relay sockets get injected with dielectric grease which effectively seals them from moisture.
All connections are butt, spade or ring connectors that are crimped and then have heat shrink tubing over them.
This is the way the race teams do their cars.

I have a 12 volt power supply I use to test wiring. It's great because it's not heavy and no battery acid. It has circuit protection so if you hook it up to something and there is a direct short it shuts off.
So today I wanted to test the window motors and I was getting nothing. What? Oh, that's right I have to turn on the key. But it didn't happen that quickly........... big laugh on me.
 

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Markos

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I have a 12 volt power supply I use to test wiring. It's great because it's not heavy and no battery acid. It has circuit protection so if you hook it up to something and there is a direct short it shuts off.
Agreed! I have one also and use it all the time. They are extremely useful and safe. I actually bought it to power DIY plating processes, but so far it has all been for testing and diagnostics.
 

Markos

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Hi Gary,

Who did the coolant neck modification for your triple 45 setup? Thanks!
 

m5bb

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I walk by this every day to work on the body. One tends to be oblivious to it but today I took all the extraneous parts off of it and took a couple photos.
Still working on the valve cover but the motor is ready to goooooooooooo.
 

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autokunst

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I walk by this every day to work on the body. One tends to be oblivious to it but today I took all the extraneous parts off of it and took a couple photos.
Still working on the valve cover but the motor is ready to goooooooooooo.
Beautiful!
 

Luis A.

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Hey Gary, looking good. Are you keeping that blue scotch lok connector under the relay? They can be bad news... why not just use a butt connector of the right size to connect all three wire ends together...?
 

m5bb

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Hey Gary, looking good. Are you keeping that blue scotch lok connector under the relay? They can be bad news... why not just use a butt connector of the right size to connect all three wire ends together...?
No Luis, all the connectors are going to butt, spade or ring connectors with heat shrink tubing. I even see a few on the engine block to change. If you're looking you can see most of those connections in the engine bay photo have already been changed. Probably didn't see the one under the relay.......... yet. All the connections are race grade or better. Found some more scotch loks under the dash today. PO really liked those things.
 

JamesE30

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Wow the engine looks fantastic, what coating or finish did you treat the Alu parts to?

Is Avus blue the original colour? (Edit: nevermind reread the original post)
What are you’re thoughts on building your car to your own specs and preferences vs originallity?

There are certain things I have changed, and the I want to change on my own car, but seeeing how anal purists are frightens me at the prospect of ever selling it one day haha
 

m5bb

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Wow the engine looks fantastic, what coating or finish did you treat the Alu parts to?

Is Avus blue the original colour? (Edit: nevermind reread the original post)
What are you’re thoughts on building your car to your own specs and preferences vs originallity?

There are certain things I have changed, and the I want to change on my own car, but seeeing how anal purists are frightens me at the prospect of ever selling it one day haha
I am building what I like and it sure doesn't get me many fans. I don't care. My car with it's special touches will be worth as much or more than an original car.
The details that I have done will blow many original cars away plus long term with a younger generation coming along a car like mine will appeal to a much larger audience.
And good grief some of these young (30's) folks are making some big bucks.

Your audience in Germany may be different. From what I see and hear from my German friends they are very conservative on their car upgrades.
Also I hear the German and other Euro governments limits the mods you can do to many cars.
I have an E28 M5 and it was parked at Road Atlanta back in 2010? The Audi's and Peugeot's were at full tilt in the racing world. I returned to my car on practice day at the Petit Lemans to find the whole Peugeot race team looking over and under my car. They wanted to see under the hood and when I told them the mods I had done to it they were amazed. They told me they would not be allowed to do those mods in France and many other Euro countries.
So I guess we have it good here in the US to be able to do pretty much whatever we want to our cars.
Let us know what you decide and send some photos please.
Gary
 

m5bb

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Today was Coupe CD day.
Period correct in 1982. Ten years into the life of this car.
Quite a variety from the old wallet CD case.
Wynton Marsalis playing famous classical trumpet airs by Vivaldi and others. Sting and a Brand New Day.
U2 Atomic Bomb, Joe Bonamassa Acoustic, En Vogue Funky Divas, UB40 Reggae and now to cap off the night.
Pat Metheny and some Jazzzzzzzz.
Moldings around doors and windows was one of today’s projects. Lots of stubborn rubber.
My hands hurt!!!
About 85%. Finish tomorrow.

You can see the stereo and CD player on the shelf in the background and my 40+ year old Infinity speakers hanging on the wall. They're definitely period correct.
 

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m5bb

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We'll the coupe got her heart back tonight. Couple of friends came over and helped guide the engine back into the engine bay without incident.
Lots of padding around just in case.
Didn't have the transmission on this time but did have the power steering pump and AC compressor. Gets a little close front to back.
I have done this 5 times now and have done it twice all by myself.

Some more engine porn.
My garage right before my helpers arrived.
Lots of padding on the front and side of the engine compartment. No dings allowed.
 

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rsporsche

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looking so excellent Gary ... need to come by and see it again soon, a lot of progress
 

JetDexter

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Yes, that is some great inspiration right there. Such nice work. I am trying to avoid the 3 year plan on mine, but the rust has different plans.
 

m5bb

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Biiig box showed up today.
You know what these are?
SEM paint does an excellent job on the black vinyl covers. Glove box, fuse box and panel for hazard and rear window heater.
 

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