E28i 535i 1988 manual resto/euro conversion

[Rthlss1]

While I wait for some parts I have taken style 5s apart to have lips polished and bolts/nuts chromed.

20220414_115011 by Jan Podržaj, on Flickr

Got rear axle rubber mountings, pitman arms and rear stabilizer links. Rear end is now solid as it should be.

20220414_112121 by Jan Podržaj, on Flickr
20220415_184612 by Jan Podržaj, on Flickr
20220415_190203 by Jan Podržaj, on Flickr
20220415_185458 by Jan Podržaj, on Flickr
20220415_185502 by Jan Podržaj, on Flickr
20220415_191602 by Jan Podržaj, on Flickr
20220415_195659 by Jan Podržaj, on Flickr
20220415_195630 by Jan Podržaj, on Flickr

While I had diff removed I gave it a quick wash to remove dirt.

20220415_184529 by Jan Podržaj, on Flickr

I also noticed that output shafts were replaced since the label on them says 2011 - that is always a good thing.

20220415_200825 by Jan Podržaj, on Flickr

[Rthlss1]

Finally euro conversion can start.
I have acquired used euro bumpers. As you can imagine if e28 in europe is being parted out it is mostly because of accident or rust issues so bumpers are rusty and bend in majority of cases.

Anyway my bumpers were in rough condition. Here is the process of their restoration.

State of them once i got them.

20211214_175203 by Jan Podržaj, on Flickr
2 by Jan Podržaj, on Flickr

Dechromed

20220127_182330 by Jan Podržaj, on Flickr
20220127_182305 by Jan Podržaj, on Flickr
20220127_182227 by Jan Podržaj, on Flickr

Welding time

20220127_184623 by Jan Podržaj, on Flickr
20220201_174119 by Jan Podržaj, on Flickr

Grinding

20220201_185659 by Jan Podržaj, on Flickr
20220127_182232 by Jan Podržaj, on Flickr
20220201_185806 by Jan Podržaj, on Flickr

Back from chrome shop

20220420_142023 by Jan Podržaj, on Flickr
20220420_142037 by Jan Podržaj, on Flickr
20220420_141158 by Jan Podržaj, on Flickr

Not perfect due to all repairs but good enough. Will have them painted inside to prevent any future rusting on weld spots.

Also managed to source the rear original Zender bumper

20220420_142729 by Jan Podržaj, on Flickr
20220420_142626 by Jan Podržaj, on Flickr

Removed USA rear bumper. Panels are intact still have the original VIN sticker.

20220421_200549 by Jan Podržaj, on Flickr
20220422_130156 by Jan Podržaj, on Flickr
20220422_124623 by Jan Podržaj, on Flickr
20220422_124629 by Jan Podržaj, on Flickr
20220422_130144 by Jan Podržaj, on Flickr

When doing bumper conversion the existing holes of USA bumper mounts can be used with some cutting inside the trunk on the passenger site. I refused to cut the rust free car so I came up with the idea to press threaded nuts inside these existing holes so no need of cutting to access the nut from the trunk. Will be a pain in the ass to install but rather spend more time than cutting the car.

20220422_175204 by Jan Podržaj, on Flickr

And i assembled bumpers to test fit fitments on the car next week

20220420_184755 by Jan Podržaj, on Flickr
20220423_192340 by Jan Podržaj, on Flickr

[stuartinmn]

Good job on restoring the bumpers!

[alkalineom3n]

Nice work, glad to see this coming along! Wish I was making as fast as progress as you!

[sheebs]

Great progress indeed! Are you going to notch the lower valance for the exhaust? I didn't mind a little cutting, but instead of replacing the entire back panel and risking the body going out of square, I only replaced up to a horizontal line which is hidden behind the bumper.

I've also been to Ljubljana believe it or not. Beautiful place. Was visiting American friends living/working in Villach Austria, and we spent an a day looping thru Slovenia and N. Italy.

Great progress! I truly enjoy reading up on restoration projects like this! It gives me inspiration on my own project as well as insight on what was done to achieve a solution.

side note: I used to work for a Slovenian company based in Ljubljana they took employees back to Ljubljana every year to experience the culture!

[muleskinner]

That's some craftsmanship with the bumpers. Look forward to seeing the continued transformation.

[Mdreamer]

I agree with the other posters about how nice your bumpers came out. Great work!

[Rthlss1]

Great progress indeed! Are you going to notch the lower valance for the exhaust? I didn't mind a little cutting, but instead of replacing the entire back panel and risking the body going out of square, I only replaced up to a horizontal line which is hidden behind the bumper.

I've also been to Ljubljana believe it or not. Beautiful place. Was visiting American friends living/working in Villach Austria, and we spent an a day looping thru Slovenia and N. Italy.

Great progress! I truly enjoy reading up on restoration projects like this! It gives me inspiration on my own project as well as insight on what was done to achieve a solution.

side note: I used to work for a Slovenian company based in Ljubljana they took employees back to Ljubljana every year to experience the culture!

Thank you guys for your feedback!!

Again small world . Yes Ljubljana is a nice small city in a day you can see it all and in 1 hour of drive you can be in Italy, Croatia...
Zender rear bumper is going to make a lower line. I have test fitted it and adjusted exhaust end tips (shortened them and re-welded position to sit higher and in the center of Zender space for exhaust tips) to fit as nice as possible.

20220428_105309 by Jan Podržaj, on Flickr
20220428_104437 by Jan Podržaj, on Flickr
20220428_195320 by Jan Podržaj, on Flickr

[Rthlss1]

USA bumper was removed and the EURO bumper was test fitted.

20220426_173833 by Jan Podržaj, on Flickr
20220426_193449 by Jan Podržaj, on Flickr
20220426_193424 by Jan Podržaj, on Flickr
20220426_193236 by Jan Podržaj, on Flickr

And the gear shift knob is now covered in new leather.
received_406105857614193 by Jan Podržaj, on Flickr
received_680463526400069 by Jan Podržaj, on Flickr
received_416334446494087 by Jan Podržaj, on Flickr

Hopefully I get the dashboard and interior back this week so I can finish work inside the car.

[1st 5er]

Dat knob

[Rthlss1]

Got the dashboard and interior back.

20220509_153737 by Jan Podržaj, on Flickr
20220509_154125 by Jan Podržaj, on Flickr
20220509_154203 by Jan Podržaj, on Flickr

Installed everything - dash vent surprisingly fast.

20220510_172615 by Jan Podržaj, on Flickr
20220510_173145 by Jan Podržaj, on Flickr
20220510_185735 by Jan Podržaj, on Flickr
20220510_193105 by Jan Podržaj, on Flickr

New leather on steering

20220510_172232 by Jan Podržaj, on Flickr

Repaired sloppy webbing on back of the seats and shortened the plastic around bowden cable so the headrest on drivers seat works again.

20220510_174344 by Jan Podržaj, on Flickr
20220510_194124 by Jan Podržaj, on Flickr
20220510_174349 by Jan Podržaj, on Flickr

[Mdreamer]

Wow! It is coming together very nicely. This makes me wish I had the skills to do all of my own work. Sigh...