displaying posts 201 to 212 of 212

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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 Yes

Started with taking the engine out to get full access to the engine bay





________________________________________

Cherry Red Rallye Project thread
WhiteBMW M140i
Posted 4th Sep 2022 at 17:55
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 thread
WhiteBMW M140i
Posted 4th Sep 2022 at 17:56
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 Smile









________________________________________

Cherry Red Rallye Project thread
WhiteBMW M140i
Posted 4th Sep 2022 at 18:04
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 thread
WhiteBMW M140i
Posted 4th Sep 2022 at 17:59
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 thread
WhiteBMW M140i
Posted 4th Sep 2022 at 17:59
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 thread
WhiteBMW M140i
Posted 4th Sep 2022 at 18:00
Denis

Regular

Location: Cambridge

Registered: 07 Sep 2004

Posts: 491

Status: Offline

Post #207
Some self-assembly required

________________________________________

Cherry Red Rallye Project thread
WhiteBMW M140i
Posted 4th Sep 2022 at 18:00
Denis

Regular

Location: Cambridge

Registered: 07 Sep 2004

Posts: 491

Status: Offline

Post #208
Mock-up



________________________________________

Cherry Red Rallye Project thread
WhiteBMW M140i
Posted 4th Sep 2022 at 18:00
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 thread
WhiteBMW M140i
Posted 4th Sep 2022 at 18:01
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 thread
WhiteBMW M140i
Posted 4th Sep 2022 at 18:05
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 thread
WhiteBMW M140i
Posted 4th Sep 2022 at 18:05
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 Thread

Few 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
Posted 5th Sep 2022 at 08:20

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