E28i 535i 1988 manual resto/euro conversion

Post your photos and videos here!
Rthlss1
Posts: 28
Joined: Feb 24, 2022 1:20 PM
Location: Slovenia

Re: E28i 535i 1988 manual resto/euro conversion

Post by Rthlss1 »

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

Image20220414_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.

Image20220414_112121 by Jan Podržaj, on Flickr
Image20220415_184612 by Jan Podržaj, on Flickr
Image20220415_190203 by Jan Podržaj, on Flickr
Image20220415_185458 by Jan Podržaj, on Flickr
Image20220415_185502 by Jan Podržaj, on Flickr
Image20220415_191602 by Jan Podržaj, on Flickr
Image20220415_195659 by Jan Podržaj, on Flickr
Image20220415_195630 by Jan Podržaj, on Flickr

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

Image20220415_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.

Image20220415_200825 by Jan Podržaj, on Flickr
Rthlss1
Posts: 28
Joined: Feb 24, 2022 1:20 PM
Location: Slovenia

Re: E28i 535i 1988 manual resto/euro conversion

Post by 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.

Image20211214_175203 by Jan Podržaj, on Flickr
Image2 by Jan Podržaj, on Flickr

Dechromed

Image20220127_182330 by Jan Podržaj, on Flickr
Image20220127_182305 by Jan Podržaj, on Flickr
Image20220127_182227 by Jan Podržaj, on Flickr

Welding time

Image20220127_184623 by Jan Podržaj, on Flickr
Image20220201_174119 by Jan Podržaj, on Flickr

Grinding

Image20220201_185659 by Jan Podržaj, on Flickr
Image20220127_182232 by Jan Podržaj, on Flickr
Image20220201_185806 by Jan Podržaj, on Flickr

Back from chrome shop

Image20220420_142023 by Jan Podržaj, on Flickr
Image20220420_142037 by Jan Podržaj, on Flickr
Image20220420_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

Image20220420_142729 by Jan Podržaj, on Flickr
Image20220420_142626 by Jan Podržaj, on Flickr

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

Image20220421_200549 by Jan Podržaj, on Flickr
Image20220422_130156 by Jan Podržaj, on Flickr
Image20220422_124623 by Jan Podržaj, on Flickr
Image20220422_124629 by Jan Podržaj, on Flickr
Image20220422_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.

Image20220422_175204 by Jan Podržaj, on Flickr

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

Image20220420_184755 by Jan Podržaj, on Flickr
Image20220423_192340 by Jan Podržaj, on Flickr
stuartinmn
Posts: 9221
Joined: Feb 12, 2006 12:00 PM
Location: Minneapolis

Re: E28i 535i 1988 manual resto/euro conversion

Post by stuartinmn »

Good job on restoring the bumpers!
alkalineom3n
Posts: 45
Joined: Nov 15, 2013 4:33 PM
Location: Rochester NY
Contact:

Re: E28i 535i 1988 manual resto/euro conversion

Post by alkalineom3n »

Nice work, glad to see this coming along! Wish I was making as fast as progress as you!
sheebs
Posts: 105
Joined: May 31, 2013 8:46 PM
Location: Los Angeles, CA

Re: E28i 535i 1988 manual resto/euro conversion

Post by 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.
bronziti wrote: Mar 29, 2022 12:44 AM 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
Posts: 1297
Joined: Sep 08, 2007 11:17 AM
Location: John Graham ATL

Re: E28i 535i 1988 manual resto/euro conversion

Post by muleskinner »

That's some craftsmanship with the bumpers. Look forward to seeing the continued transformation.
Mdreamer
Posts: 390
Joined: Feb 12, 2006 12:00 PM
Location: Atlanta, Georgia

Re: E28i 535i 1988 manual resto/euro conversion

Post by Mdreamer »

I agree with the other posters about how nice your bumpers came out. Great work!
Rthlss1
Posts: 28
Joined: Feb 24, 2022 1:20 PM
Location: Slovenia

Re: E28i 535i 1988 manual resto/euro conversion

Post by Rthlss1 »

sheebs wrote: May 01, 2022 9:08 PM 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.
bronziti wrote: Mar 29, 2022 12:44 AM 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.

Image20220428_105309 by Jan Podržaj, on Flickr
Image20220428_104437 by Jan Podržaj, on Flickr
Image20220428_195320 by Jan Podržaj, on Flickr
Rthlss1
Posts: 28
Joined: Feb 24, 2022 1:20 PM
Location: Slovenia

Re: E28i 535i 1988 manual resto/euro conversion

Post by Rthlss1 »

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

Image20220426_173833 by Jan Podržaj, on Flickr
Image20220426_193449 by Jan Podržaj, on Flickr
Image20220426_193424 by Jan Podržaj, on Flickr
Image20220426_193236 by Jan Podržaj, on Flickr

And the gear shift knob is now covered in new leather.
Imagereceived_406105857614193 by Jan Podržaj, on Flickr
Imagereceived_680463526400069 by Jan Podržaj, on Flickr
Imagereceived_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
Posts: 21009
Joined: Jun 13, 2008 12:15 AM
Location: Cypress
Contact:

Re: E28i 535i 1988 manual resto/euro conversion

Post by 1st 5er »

Dat knob :ohyeah:
Rthlss1
Posts: 28
Joined: Feb 24, 2022 1:20 PM
Location: Slovenia

Re: E28i 535i 1988 manual resto/euro conversion

Post by Rthlss1 »

Got the dashboard and interior back.

Image20220509_153737 by Jan Podržaj, on Flickr
Image20220509_154125 by Jan Podržaj, on Flickr
Image20220509_154203 by Jan Podržaj, on Flickr

Installed everything - dash vent surprisingly fast.

Image20220510_172615 by Jan Podržaj, on Flickr
Image20220510_173145 by Jan Podržaj, on Flickr
Image20220510_185735 by Jan Podržaj, on Flickr
Image20220510_193105 by Jan Podržaj, on Flickr

New leather on steering

Image20220510_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.

Image20220510_174344 by Jan Podržaj, on Flickr
Image20220510_194124 by Jan Podržaj, on Flickr
Image20220510_174349 by Jan Podržaj, on Flickr
Mdreamer
Posts: 390
Joined: Feb 12, 2006 12:00 PM
Location: Atlanta, Georgia

Re: E28i 535i 1988 manual resto/euro conversion

Post by Mdreamer »

Wow! It is coming together very nicely. This makes me wish I had the skills to do all of my own work. Sigh...
Rthlss1
Posts: 28
Joined: Feb 24, 2022 1:20 PM
Location: Slovenia

Re: E28i 535i 1988 manual resto/euro conversion

Post by Rthlss1 »

Mdreamer wrote: May 13, 2022 12:46 AM Wow! It is coming together very nicely. This makes me wish I had the skills to do all of my own work. Sigh...
Thanks. I do it with major help from my father who is a great craftsman.
Rthlss1
Posts: 28
Joined: Feb 24, 2022 1:20 PM
Location: Slovenia

Re: E28i 535i 1988 manual resto/euro conversion

Post by Rthlss1 »

Installed rear EURO bumper and Zender apron.

Some before/after side comparison.

Image20220420_171613 by Jan Podržaj, on Flickr
Image20220520_203435 by Jan Podržaj, on Flickr
Image20220520_204028 by Jan Podržaj, on Flickr
Image20220520_203547 by Jan Podržaj, on Flickr
Image20220520_203948 by Jan Podržaj, on Flickr

Wasn't able to save the original antenna (will use it for parts for other projects) so I bought another Hirschmann antenna that works perfectly and I think it is period correct as well.¸

Image20220516_173159 by Jan Podržaj, on Flickr
Image20220516_174954 by Jan Podržaj, on Flickr
Rthlss1
Posts: 28
Joined: Feb 24, 2022 1:20 PM
Location: Slovenia

Re: E28i 535i 1988 manual resto/euro conversion

Post by Rthlss1 »

EURO goodies from Germany arrived

Image20220420_171613 by Jan Podržaj, on Flickr

- front metal euro valance
- NEW ZENDER ORIGINAL front apron
- MTech trunk spoiler
- euro blinkers
- another euro front chrome bumper

Image20220526_094024 by Jan Podržaj, on Flickr

Test fitting

Image20220526_201823 by Jan Podržaj, on Flickr

Due to rust on euro metal valance I only bought it for measurements to cut the holes on USA valance.
Rthlss1
Posts: 28
Joined: Feb 24, 2022 1:20 PM
Location: Slovenia

Re: E28i 535i 1988 manual resto/euro conversion

Post by Rthlss1 »

Cut the openings to make "euro" valance.

Image2 by Jan Podržaj, on Flickr
Image20220531_172941 by Jan Podržaj, on Flickr

Test fitted front euro bumper and zender apron.

Image20220531_173119 by Jan Podržaj, on Flickr

Will be running fog light delete plates

Image[/url]20220531_181811 by Jan Podržaj, on Flickr
Image20220531_181819 by Jan Podržaj, on Flickr

Removed old glue and repair broken off thread from Mtech trunk lip

Image20220530_105309 by Jan Podržaj, on Flickr
Image20220601_114353 by Jan Podržaj, on Flickr
Image20220601_165844 by Jan Podržaj, on Flickr

There was a chip of plastic missing on Mtech plastic - I put some liquid plastic to fill it and sanded it. Since I had the plastic tube opened I cut off connectors from USA blinkers and attached them to EURO blinkers and sealed them with plastic.

Image20220601_114432 by Jan Podržaj, on Flickr
Image20220601_121033 by Jan Podržaj, on Flickr
Image20220601_114416 by Jan Podržaj, on Flickr

Thanks to the guy who did great write up http://speed.academy/bmw-e28-euro-bumpe ... 4716796875

Sanded rubber a bit to put some rubber paint on

Image20220601_171336 by Jan Podržaj, on Flickr
Image20220601_170601 by Jan Podržaj, on Flickr

Got the wheels back - now with polished lips and new nuts/bolts

Image20220602_200627 by Jan Podržaj, on Flickr
Image20220602_202103 by Jan Podržaj, on Flickr
Rthlss1
Posts: 28
Joined: Feb 24, 2022 1:20 PM
Location: Slovenia

Re: E28i 535i 1988 manual resto/euro conversion

Post by Rthlss1 »

Took out the grill and headlights for proper cleaning.

Image20220609_172734 by Jan Podržaj, on Flickr

Polished headlight rings and cleaned grill.

Image20220609_190326 by Jan Podržaj, on Flickr
Image20220609_221359 by Jan Podržaj, on Flickr
Image20220609_192615 by Jan Podržaj, on Flickr
Image20220609_192642 by Jan Podržaj, on Flickr

Installed KAW springs - 45 mm front / - 40 mm rear. As always happy with how KAW springs feel while driving. Stiff but not hard through holes.

Image20220615_175421 by Jan Podržaj, on Flickr
Image20220615_175551 by Jan Podržaj, on Flickr
Image20220615_191437 by Jan Podržaj, on Flickr
Image20220615_191455 by Jan Podržaj, on Flickr
Image20220615_191508 by Jan Podržaj, on Flickr

Marked and drilled holes for Mtech trunk spoiler.

Image20220615_184322 by Jan Podržaj, on Flickr

Got a Zender front apron and trunk lip plastic from a paint shop and installed them.

Image20220623_190100 by Jan Podržaj, on Flickr
Image2 by Jan Podržaj, on Flickr
Image20220624_114029 by Jan Podržaj, on Flickr

Before/after conversion

Image20220420_172640 by Jan Podržaj, on Flickr
Image20220623_202608 by Jan Podržaj, on Flickr

Took the car to MOT - passed with no issues.

Image20220624_121245 by Jan Podržaj, on Flickr

Meanwhile I also bought another 535iA 156k miles from California with broken auto transmission.

Image20220512_174159 by Jan Podržaj, on Flickr
Image20220512_174348 by Jan Podržaj, on Flickr
Image20220512_180952 by Jan Podržaj, on Flickr

Replaced transmission and after service shifts like charm.

Image20220603_164946 by Jan Podržaj, on Flickr

Also I converted it to EURO look.

Image20220622_174123 by Jan Podržaj, on Flickr
Image20220622_174058 by Jan Podržaj, on Flickr
Image20220622_174238 by Jan Podržaj, on Flickr

Front bumper was already tucked in but still not for my taste.

Image20220525_181438 by Jan Podržaj, on Flickr

Got the opportunity to compare sport vs comfort seats. Must say that for e28 comfort seats are a better choice - seat armrest do the thing and soffer/longer leg support. But sport seats do look much better.

Image20220622_174958 by Jan Podržaj, on Flickr
Mdreamer
Posts: 390
Joined: Feb 12, 2006 12:00 PM
Location: Atlanta, Georgia

Re: E28i 535i 1988 manual resto/euro conversion

Post by Mdreamer »

When I first opened the thread and saw your black car I thought to myself, "I thought his car was white?" :laugh:

Thanks for keeping us abreast of your progress. I really like how the white car is progressing, and I agree with your findings regarding comfort versus sport seats. The sports definitely look the part, but that armrest is the business on longer drives! Are you going to keep the automatic in the black car?
Rthlss1
Posts: 28
Joined: Feb 24, 2022 1:20 PM
Location: Slovenia

Re: E28i 535i 1988 manual resto/euro conversion

Post by Rthlss1 »

Mdreamer wrote: Jun 24, 2022 10:54 AM When I first opened the thread and saw your black car I thought to myself, "I thought his car was white?" :laugh:

Thanks for keeping us abreast of your progress. I really like how the white car is progressing, and I agree with your findings regarding comfort versus sport seats. The sports definitely look the part, but that armrest is the business on longer drives! Are you going to keep the automatic in the black car?
Quick paint job and she is black :D

Thanks.

I am keeping it automatic. I drove it 300 miles this weekend and in sport mode can be driven on curvy roads as well. e36 318is and e30 325i were having trouble keeping up.

Image20220626_190923 by Jan Podržaj, on Flickr
cek
Posts: 9080
Joined: Mar 18, 2013 6:25 PM
Location: Durango
Contact:

Re: E28i 535i 1988 manual resto/euro conversion

Post by cek »

Really great work. Motivating me to do the euro swap on Maytag!

Alpine E28s converted to 6-speeds are the best.
Rthlss1
Posts: 28
Joined: Feb 24, 2022 1:20 PM
Location: Slovenia

Re: E28i 535i 1988 manual resto/euro conversion

Post by Rthlss1 »

cek wrote: Jun 27, 2022 12:54 PM Really great work. Motivating me to do the euro swap on Maytag!

Alpine E28s converted to 6-speeds are the best.
Thanks. Just a few days ago I was checking your 535is zinno thread. Nice work!

From what car 6 - speed tranny is used for conversion? E39?
cek
Posts: 9080
Joined: Mar 18, 2013 6:25 PM
Location: Durango
Contact:

Re: E28i 535i 1988 manual resto/euro conversion

Post by cek »

Rthlss1 wrote: Jun 29, 2022 6:30 AM
cek wrote: Jun 27, 2022 12:54 PM Really great work. Motivating me to do the euro swap on Maytag!

Alpine E28s converted to 6-speeds are the best.
Thanks. Just a few days ago I was checking your 535is zinno thread. Nice work!

From what car 6 - speed tranny is used for conversion? E39?
Ha! Maytag's swap is a 5-speed, but the shift knob is from an E34 (I previously had an E34 540i M-Sport and had kept a semi-broken knob I replaced).

MInerva has a 6-speed from an E46 M3.
Post Reply