E28 M5: Bringing it back to life (UPDATED 8/14/16)

1st 5er · Post by **1st 5er** » Dec 14, 2015 10:05 PM

Glad to see things progressing.

I need to pay you a visit.

Post by **tig** » Dec 14, 2015 11:32 PM

MilanoFc wrote:
cek wrote:Nice work!

With black M5s being so common, are you going for a color change?
I will actually be going with lapis blue, which is what the euro shell color is originally.

Great color! I approve.

MilanoFc · Post by **MilanoFc** » Dec 20, 2015 10:46 PM

1st 5er wrote:Glad to see things progressing.

I need to pay you a visit.

Anytime! best bet would be Sat, since on weekdays I only work on it after work.

MilanoFc · Post by **MilanoFc** » Dec 20, 2015 10:48 PM

cek wrote:
MilanoFc wrote:
cek wrote:Nice work!

With black M5s being so common, are you going for a color change?
I will actually be going with lapis blue, which is what the euro shell color is originally.
Great color! I approve.

MilanoFc · Post by **MilanoFc** » Dec 20, 2015 11:05 PM

So far I only have a small update. 3 out of 4 doors have been completed of body work, removed the wiring harness from the shell, and also took off trunk area parts from the M5

Received my IE rear camber/toe kit and placed an ordered on a new trunk and lt fender

MilanoFc · Post by **MilanoFc** » Dec 22, 2015 11:26 PM

Removed the tail lamp panel off the M5 body to gain access to the floor pan. Will be cutting and welding the a floor section into euro body for the rusted area that needs replacement

MilanoFc · Post by **MilanoFc** » Jan 03, 2016 11:39 PM

So I took advantage of the days off and started the cutting and trimming on both car. I also received the spot welder for when the new tail lamp panel and the roof goes back on.

On order I have the driver fender and trunk that I should be getting soon. On the roof, I figured that trying to remove the one off the M5 would be a hit or miss. So I went ahead and ordered a new one. Dealer told me that it would take 3-4 weeks, so now to play the waiting game for it to come in. But I will go ahead and use that down time to move on with other tasks. Planning on having the rear floor/ tail lamp panel completed this week hopefully so I can start the underbody process

MilanoFc · Post by **MilanoFc** » Jan 04, 2016 11:38 PM

Got some action today. Got the right side of the floor welded in. Not bad for a Monday!

Plus I got the M fabric reproduction that a fellow member is selling.

MilanoFc · Post by **MilanoFc** » Jan 13, 2016 11:06 PM

After the floor and side reinforcements were welded in, I decided to hold off on welding the tail lamp panel into place. Being that I did not have the trunk I did not to move on because I wanted to make sure on the fitment of the tail lamp panel, lights, and quarter corners that we will be welding in place. So after waiting 3 weeks I get the trunk and the fenders that were on order. Now all I have to wait for is the roof. And while I was waiting on that, I went ahead and removed the rear subframe as well to get it prepped for the camber/toe kit so I can send it off to the powder coat.

MilanoFc · Post by **MilanoFc** » Jan 22, 2016 9:48 PM

Back for an update! Finally got the tail lamp panel, quarter inserts, side marker holes, and quarter gutter welded in. Have to clean up the welds to get going on the rest of the body work. Finally looking more like a E28. Will let the pics do the rest of the talking!

Lastly, got the valve cover and penlum from Carl at Korman. Thanks for the great work!

leadphut · Post by **leadphut** » Jan 23, 2016 1:02 PM

holy thread revival. forgot about this car.

great to see you're back. looking forward to progress. love the new engine pieces; they'll look great.

Hffvdbl · Post by **Hffvdbl** » Jan 23, 2016 1:19 PM

Very cool project, can't wait to see it at TexFest!

MilanoFc · Post by **MilanoFc** » Jan 28, 2016 11:30 PM

Thanks guys!.. So far I have finished welding in the tail lamp panel. Its brazed in like the factory and seam sealed up the openings, all that needs to be done is file in the line on the tail lamp panel for the OE look to finalize it. Also decided to take apart the rear subframe to remove all the bushings and add the alignment kit so I can hopefully send it in to powder coat next week. I also got the missing piece to the puzzle by surprise! Time to really get this going since i don't have an excuse to say I can't move on.

MilanoFc · Post by **MilanoFc** » Feb 03, 2016 11:04 PM

Got the rear subframe ready. Now just need to remove the trailing arm bushings and hub bearing to drop them off for PC. Bodywork has started on the quarter panels so its starting to look more like a E28. I will be attempting to have roof panel installed by Sunday, but I also have engagement photo shoot that day so who know now

Measuring and welding

Grinded and slotted

MilanoFc · Post by **MilanoFc** » Feb 14, 2016 12:13 AM

Well it has been a busy week. Roof is done! Let me just say that it was a PITA to remove the roof panel. I counted 53 spot welds on the driver side gutter, which I had to carefully grind all spot welds to separate the panel since I wanted to leave the inner sheet metal intact so I could spot weld the new panel in. Other than that the install was a breeze with all thats left is to mig weld the 6 sunroof brackets and braze the 4 corners. Finally its a true shell.

Other progress that was done was sending in the suspension parts to powder coat. Removing the trailing arm bushing was a royal pain. Attempted several ways to remove them and none would budge. Final we just decided to burn out the rubber and air chisel out the outer sleeve. After 2 tips it was done. Second set was done in 20 mins compared to the 2 hours when we tried the first arm. Special thanks to Mark @ Royalty Medal Finishing. Overall finish is outstanding and the turnaround time was superb.

I also got my E31 calipers in, so thats in the works as well. Still debating what color/ finish to go with.

Kyle in NO · Post by **Kyle in NO** » Feb 14, 2016 1:10 AM

People out there are wanting the euro cars with no sunroofs, and here you are installing one!

86GT635 · Post by **86GT635** » Feb 14, 2016 2:13 AM

Yea, you're definitely crazy. If you don't own that body shop, I'm sure that's a 10k bill before paint.
I wish you picked a better shell, even a 525i. This is crazy cool, take more pics!!!!

MilanoFc · Post by **MilanoFc** » Feb 14, 2016 11:30 AM

Kyle in NO wrote:People out there are wanting the euro cars with no sunroofs, and here you are installing one!

Euro body originally had a sunroof. I actually tried to get a non sunroof panel, but they are NLA.

MilanoFc · Post by **MilanoFc** » Feb 14, 2016 11:35 AM

86GT635 wrote:Yea, you're definitely crazy. If you don't own that body shop, I'm sure that's a 10k bill before paint.
I wish you picked a better shell, even a 525i. This is crazy cool, take more pics!!!!

Haha, good thing we own the body shop ( father and I). Shell was actually not that bad. The reason why I got it was because I knew exactly what I was getting myself into when I bought it. It was bare so everything was visible and was better off than buying another shell and finding surprises as I was tearing it down. Plus I like to challenge myself

.

MilanoFc · Post by **MilanoFc** » Feb 29, 2016 10:43 PM

Small update. Body is looking more promising. Getting close to getting this step done with and to get going with the fun stuff!

Removed the interior out and took it home to keep it safe and clean

Also got my power flex replacement bushings

MilanoFc · Post by **MilanoFc** » Mar 13, 2016 11:15 AM

Body work is 90% completed. Every panel that needed attention is done and primed. The focus is on getting the engine bay, trunk area, and underbody ready so I can install the suspension, brakes, and harness. First I needed to transfer the M5 brackets that the euro body did not have. I'm also waiting on the stud welder to come in so I can weld the studs for the battery cable, brake lines, and misc brackets.

EventuallyAyrton · Post by **EventuallyAyrton** » Mar 13, 2016 8:04 PM

You're doing an amazing job and I can't wait to see the finished product! Keep the updates coming

(Blue brake calipers would be interesting. You could match them to the rest of the paint)

MilanoFc · Post by **MilanoFc** » Apr 10, 2016 1:15 PM

It has been almost a month of not being able to work on the car since I had two customer jobs I had to attend to. So yesterday we pushed the body out of the shop so I could pressure wash the sand off from the blasting and degrease the engine bay. Starting this week its to the two post lift and began the removal of all the underbody components to get it undercoated and paint the engine bay/ trunk area to start putting in all the wiring, suspension and brake components.

During the time I was also able to pick up a stud welder (to be able to hold down the batt cable and brake lines like factory) and purchased all the remaining suspension parts. Time to hustle as I have roughly 4 months to get this done

86GT635 · Post by **86GT635** » Apr 11, 2016 1:12 PM

Get it man! Rooting for you.

Pavel · Post by **Pavel** » Apr 12, 2016 10:34 AM

Oh wow didn't pay attention that this is happening in Houston.

Following now. Scrolled back in the past and recognized the euro shell.

1st 5er · Post by **1st 5er** » Apr 12, 2016 12:38 PM

Pavel wrote:... recognized the euro shell.

I've, we've, if you're interested, gotta make a trip out there.

MilanoFc · Post by **MilanoFc** » Apr 12, 2016 11:26 PM

86GT635 wrote:Get it man! Rooting for you.

Thanks!

Pavel wrote:... recognized the euro shell.

1st 5er wrote:I've, we've, if you're interested, gotta make a trip out there.

Pavel, it's actually happening in your backyard if you stay in Sugar Land, Im off 90s & BW8. Feel free to stop by. Sherman is due to come out and check it out.

MilanoFc · Post by **MilanoFc** » Apr 12, 2016 11:41 PM

So shell has made it to the lift and got straight to business. Out with the old and started getting it ready for the new. Got my CD studs in today and went right at it. I am so glad I invested in the welder. My biggest worry of the whole body transfer was figuring out how to hold all the extra harness and brake lines. Well that has been figured out and I feel like I've accomplished a milestone.

LeiseyJr · Post by **LeiseyJr** » Apr 13, 2016 9:46 PM

1st 5er wrote:

Pavel wrote:... recognized the euro shell.
I've, we've, if you're interested, gotta make a trip out there.

Add me to the roster

MilanoFc · Post by **MilanoFc** » Apr 17, 2016 6:09 PM

Okay guys, I have hit a wall and need some help/ input. Before starting I was aware of "all" the differences on the 2 bodies. Well yesterday I noticed the biggest obstacle, the rear floor crossmember. At first I thought it was just to swap the rear sway bracket and done. Well we needed to fabricate the base with a angle to expand the difference in length. That was done and I felt relived, but than I questioned the differential mount and compared them to find out I have an issue. Come to find out Pre-85 have a different xmember to 85- up. My thought is to do the same as we did with the sway brackets and make a bracket to shift the diff mount. So my question is, has anyone ran into this before and/ or what are my alternatives. Much thanks in advance. Pic for reference below.

Fabricated Stab mount base

Pre- 85

Post- 85

MilanoFc · Post by **MilanoFc** » Apr 24, 2016 5:30 PM

Well I decided to give myself a break on the rear end and figured I would jump to the front and underside so I could run the wiring and firewall components since it would be the most time consuming task due to the amount of items that run through it. So between yesterday and today I finished undercoating the wheel wells and underside up to the rear seat area(used Wurth SKS), painted the engine bay, and radiator support. So 1/3 of the car is painted!

Before:

After:

86GT635 · Post by **86GT635** » Apr 24, 2016 8:00 PM

Is that lapis blue?

MilanoFc · Post by **MilanoFc** » Apr 25, 2016 5:51 PM

86GT635 wrote:Is that lapis blue?

Yes it is.

MilanoFc · Post by **MilanoFc** » Apr 30, 2016 7:01 PM

Small update. Just trying to button up all the suspension and have it ready for when we are done with the rear diff mount. Sand blasted the rear diff earlier this week and painted it today with POR15 top coat. Cleaned up the firewall insulator and decided to add some heat reflective film from Pegasus to preserve it. It really helped to firm it up so I'm happy with the results. I am still debating if I should stop where I did or do the complete insulator to the tunnel. All the suspension bushing have been installed and I'll be going in tomorrow to assemble the rear diff plus to install the hub/ bearings on the 4 corners.

Pavel · Post by **Pavel** » May 05, 2016 2:33 PM

Holy smoke!

And yes I am very close by. I will stop by soon!

86GT635 · Post by **86GT635** » May 05, 2016 3:25 PM

Please be sure to remove the paint in the joint between the bottom of the strut housing and steering arm. Nice work, really stoked to see how the lapis will look.

1st 5er · Post by **1st 5er** » May 06, 2016 8:24 AM

Pavel wrote:Holy smoke!

And yes I am very close by. I will stop by soon!

I talked to Marc yesterday about doing a TF mini meet at his place so we could all (all that want to attend) slobber all over his masterpiece, and then go grab burgers in LSB&F style.

He said Sundays were best, so grab a calendar.

BRRV · Post by **BRRV** » May 06, 2016 11:37 AM

Yes please I'm following and would love to go. Road trip...

(I had no idea the tail piece was so complex - I'll eventually need one on mine I'm afraid *sigh*)

MilanoFc · Post by **MilanoFc** » May 08, 2016 6:59 PM

86GT635 wrote:Please be sure to remove the paint in the joint between the bottom of the strut housing and steering arm. Nice work, really stoked to see how the lapis will look.

Thanks! I test fitted them before putting them on the car and had to file the paint off some.

MilanoFc · Post by **MilanoFc** » May 08, 2016 7:07 PM

1st 5er wrote:
Pavel wrote:Holy smoke!

And yes I am very close by. I will stop by soon!

I talked to Marc yesterday about doing a TF mini meet at his place so we could all (all that want to attend) slobber all over his masterpiece, and then go grab burgers in LSB&F style.

He said Sundays were best, so grab a calendar.

Let me know what date you guys come up with. Just make sure it isn't the next two following Sunday's as I have those planned already. ( Fiancee's graduation ceremony and friend 's B-day Boil).

MilanoFc · Post by **MilanoFc** » May 08, 2016 8:28 PM

After much R&D for the diff mount, its finally completed and the vehicle has touched ground as of today!

Once that was completed my mission was to finish up the rest of the undercoating, install all the lines that run underneath, and install the rear suspension. I have pictures of the during and after of the mount we fabricated. Once the undercoat was applied it looks as if it was like that from the factory. Very happy with the results.

Next phase will be to start transferring all the wiring from the M5 over. Slowly its starting to take its form.

JLav211 · Post by **JLav211** » May 13, 2016 4:22 PM

Great googly moogly, you are committed. I'm more impressed you remembered to bump your old thread!

MilanoFc · Post by **MilanoFc** » May 15, 2016 11:04 PM

JLav211 wrote:Great googly moogly, you are committed. I'm more impressed you remembered to bump your old thread!

Thanks!

MilanoFc · Post by **MilanoFc** » May 15, 2016 11:35 PM

My plan last week was to have the wiring in by the end of this weekend. Well being that the interior was bare and I wanted to remove the sound deadening pads from the trunk area before paint, I figured why not just do the complete floorboard. I had the idea to remove the complete padding in the cabin area, but decided to just remove the cracked ones and leave the ones intact alone. Once that was done I looked into installing new padding on the complete floor for additional sound deadening. For starters that would've cost lots of time to do it neatly. So a friend suggested to looking into the sprayable sound deadening, cost would've been almost the same but much quicker to do. So we looked into it and on order we had the Second Skin Spectrum on its way! I srayed 3 coats and I must admit I'm happy with the results! The panels have a significant change in the way sound travels through it when you tap on it. Eliminates the sound also immediately and the finish is great! I originally wanted to paint the trunk area, but with the second skin applied I don't think its necessary.

Before:

After:

trevmmeister · Post by **trevmmeister** » May 20, 2016 12:04 AM

Love every bit of it.

MilanoFc · Post by **MilanoFc** » May 22, 2016 1:55 PM

So this week was very successful. I was having cold feet once I started removing the wiring harness, but I got myself together and went to town on it. At the end it came out great and was just a big scare. Once I had removed all the components off the firewall, I noticed the a/c unit drain and mount brackets for abs module weren't on the other body. So I measured, test fitted, and stud welded the mounting studs that weren't on the body for the a/c and I removed/installed the brackets for the abs using body adhesive to bond onto the firewall since I did not want to mess with the welder anymore being that I have sprayed the floor already.

My biggest issue was the firewall insulator. It pretty much came apart in my hands so after doing some research and trying to find a solution my options was to try to find one, but knew that was a slim chance, or fabricate one. I contacted Second skin and he had my solution. They have a foam with hard vinyl backing that is similar to the OE insulator, which is call luxury liner pro. Comes in a roll so you have to cut to fit. I though it was going to be a hassle, but I'm happy with the end result and will be buying more of it to finish off the floor area. My main concern was to install the firewall insulator at the moment since I wanted to run the wiring while it was fresh in my head. (Please excuse some of the pic quality as I'm using my old phone since I broke mines and keep forgetting my camera chip)

white chocolate · Post by **white chocolate** » May 22, 2016 2:47 PM

That's an incredible amount of work!

Keep it up, excited to see it finished.

1st 5er · Post by **1st 5er** » May 25, 2016 9:45 AM

Hopeful to get to see it in the metal this Sunday.

Fingers crossed.

Adam W in MN · Post by **Adam W in MN** » May 25, 2016 2:36 PM

This is amazing.

geordi · Post by **geordi** » May 25, 2016 11:54 PM

Wow… just WOW!