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| Author | Subject: Denis's Rallye |
 Denis
Regular  Location: Cambridge Registered: 07 Sep 2004 Posts: 491 Status: Offline |
Post #201
Even though the car looked good in photos – up close it was very different: plenty of dents and scratches. Lacquer started to lift on the roof with the roof turning pink.Also, with plenty of rust on the underside – I have decided to tidy up the bodywork  Started with taking the engine out to get full access to the engine bay    ________________________________________ Cherry Red Rallye Project threadWhiteBMW M140i |
 Posted 4th Sep 2022 at 17:55
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Denis
Regular Location: Cambridge Registered: 07 Sep 2004 Posts: 491 Status: Offline |
Post #202
While pocking under the driver’s side wheel arche – found several rust holes, including in to the cabin, so dashboard had to come out   ________________________________________ Cherry Red Rallye Project threadWhiteBMW M140i |
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Posted 4th Sep 2022 at 17:56
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Denis
Regular Location: Cambridge Registered: 07 Sep 2004 Posts: 491 Status: Offline |
Post #203
Jet washing the front end showed lots of rust on the driver’s side chassis rail. As the passenger side rail had some damage (due to hitting a barrier at Croft a while back) – I started investigating options on what to do. Having looked at several 3dr cars – all of them had rust issues. I came across a really clean 5dr shell that was a suitable donor       ________________________________________ Cherry Red Rallye Project threadWhiteBMW M140i |
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Posted 4th Sep 2022 at 18:04
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Denis
Regular Location: Cambridge Registered: 07 Sep 2004 Posts: 491 Status: Offline |
Post #204
Decision was to replace rusted metal, so I carried on taking things off from Rallye.Windscreen came out (first time I attempted to cut one out).  ________________________________________ Cherry Red Rallye Project threadWhiteBMW M140i |
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Posted 4th Sep 2022 at 17:59
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Denis
Regular Location: Cambridge Registered: 07 Sep 2004 Posts: 491 Status: Offline |
Post #205
Sound deadening out. After trying various methods – the best one was to heat it up with hot air gun and it just pealed off in large pieces. ________________________________________ Cherry Red Rallye Project threadWhiteBMW M140i |
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Posted 4th Sep 2022 at 17:59
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Denis
Regular Location: Cambridge Registered: 07 Sep 2004 Posts: 491 Status: Offline |
Post #206
The next step was to make it easy to get to the underside of the car. Having looked at what rotisseries were available (proper ones = too expensive, e-bay ones = not well made), I decided to build my own.A good excuse to buy some more tools   ________________________________________ Cherry Red Rallye Project threadWhiteBMW M140i |
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Posted 4th Sep 2022 at 18:00
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Denis
Regular Location: Cambridge Registered: 07 Sep 2004 Posts: 491 Status: Offline |
Post #207
Some self-assembly required ________________________________________ Cherry Red Rallye Project threadWhiteBMW M140i |
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Posted 4th Sep 2022 at 18:00
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Denis
Regular Location: Cambridge Registered: 07 Sep 2004 Posts: 491 Status: Offline |
Post #208
Mock-up  ________________________________________ Cherry Red Rallye Project threadWhiteBMW M140i |
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Posted 4th Sep 2022 at 18:00
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Denis
Regular Location: Cambridge Registered: 07 Sep 2004 Posts: 491 Status: Offline |
Post #209
Lifting mechanism, so that you can pick up the shell from axle stands and lift it to any hight (allowing it to spin 360deg). Used rear hubs from the donor 306 to make the pivots. ________________________________________ Cherry Red Rallye Project threadWhiteBMW M140i |
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Posted 4th Sep 2022 at 18:01
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Denis
Regular Location: Cambridge Registered: 07 Sep 2004 Posts: 491 Status: Offline |
Post #210
A bit of paint transformed it!Complete mechanism with the ability to lock rotation (brake drums drilled for locking pin)     ________________________________________ Cherry Red Rallye Project threadWhiteBMW M140i |
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Posted 4th Sep 2022 at 18:05
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Denis
Regular Location: Cambridge Registered: 07 Sep 2004 Posts: 491 Status: Offline |
Post #211
Made several attachments for the front: for strut tops and for bumper attachments (you’ll see later why).   (more to come) ________________________________________ Cherry Red Rallye Project threadWhiteBMW M140i |
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Posted 4th Sep 2022 at 18:05
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ben306
Seasoned Pro  Location: North West Registered: 17 Jan 2006 Posts: 2,926 Status: Offline |
Post #212
Proper job this.I've the same issues regarding the rust. Managed to patch up where I can to keep it going but at some point I'll have to bite the bullet and go along these lines. Keep us updated as its great seeing the progress. ________________________________________ My 306 Rallye Project ThreadFew recent Youtube track videos, more on my channel Pair of Rallye's doing a few laps of Anglesey Lap of Anglesey Coastal 3 sisters circuit Few laps at Blyton |
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Posted 5th Sep 2022 at 08:20
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