Last weekend I did indeed get the rear calipers refitted, and to be honest that's about all that's happened since last weeks' post. Being on night shift, I've had quite a tired week this week and haven't been able to find the energy or willpower to drag myself up into that cold garage and get on with it.

Enough excuses, I'll get the rear axle finished this week and hopefully the steering too. Refitting the clucth shouldn't be too much trouble, the prop will be done at the same time (that reminds me, I need to paint the welded joint) although the clutch might require a run to Cowbridge to get some bolts to hold the pressure plate on as i had to cut them off to remove it.

Hmm... keep reading!

Just another quick update this morning.

I've finally recieved the M14x1.25 die from china that i ordered. Problem is that as it was chinese made it's not very good and the threads it cuts are too small. I ran it up the ends of the steering rack, leaving about 30mm of thread untouched, and then threaded the extensions on. Where I had used the die, they wound on but are clearly loose, and where I haven't used the die they are way too tight and don't wind on at all. Grrrrr!

Also I have cleaned and painted the rear calipers which i hope to re-fit today. This afternoon I hope to get the rear axle all finished. I can then fit the spare set of rear wheels and put it back on the floor.

After marking the propshaft to length (I sprayed the join with primer, and the shadow pn the inner shaft marks the position) I removed it from the car and tack welded it.

And here's the joing after it was fully TIG welded. Looks neat and hopefully will be nice and strong.

Here at last are some more pics. This shows the trial fitment of the propshaft


Here's the front coupling, as you can see there is a slight offset in the shaft but hopefully the flexible coupling at the front and the CV joint at the back will take this easily.



And here's the completed steering shaft extension. You can see the silver coloured centre UJ, this is the part I bought from CBS and welded in.

After spending my afternoon yesterday helping my sister finish off her horse-box project, I had a bit of time free this evening before work to carry on with some things in the garage.

I painted the completed steering extension shaft to stop it rusting, and I'll fit it tomorrow hopefully.

I then completed the trial fitment of the propshaft. With the thinner piece free to slide inside the larger front end, I bolted both ends to their drive flanges. I then sprayed grey primer all over the join where they met. This gives me an accurate alignment mark to put it back to, as I had to separate the halves again to remove them from the car.

With the to halves of propshaft removed, i wire brushed the end of the larger piece to remove all the paint for about half an inch up it's length, this is to allow it to be wleded to the inner piece. I also wire brushed 2 very small sections on the inner piece (brushing it all would have removed my previously painted on alignment mark) and slid them back together up to the alignment paint. I made sure the 2 ends were square and tack welded them together at the two cleaned up points. I Rotated it to make sure they were both running true, and then fully wire brushed the whole joint. I'll have that professionally TIG welded very shortly (and FOC!) but it will have to wait till I take the engine out to replace the clutch to be re-fitted.

I took some pics and will post them tomorrow - if I get time.

Well I managed to steal another hour in the garage today. Actually the first hour was spent out on the driveway, i began to remove the brake flexi lines from the rear ofthe beemer, and they look to be in a good serviceable condition so will be re-used on the locost.

I was however unable to remove the calipers as the bolts are stuck fast, and I need my electric impact gun to get them off - which is still away with Machine Mart getting fixed. I may just buy some more sockets to replace the ones i broke removing the wheels which may allow me to remove them manually but money is a little tight at the mo so we'll see.

When it began to rain I moved inside into the garage and had a go at finishing the steering shaft. I modified the new extension shaft I had recieved from CBS and cut my old shaft down to suit it. They fit together nicely, but my welder is all out of wire, and as these are critical welds, i will wait till I have plenty wire to finish this - probably on the weekend.

With some time left over I decided to make use of it by starting the next item on the list and plan out the routing of the solid and flexi brake lines. I think i have it all mapped out but I need to compete the removal of the flexi lines from the beemer, and install the front calipers to actually start it.

So I moved on to the next item (that's item 4 for those keeping score) and started to modify the propshaft. I cut out the centre universal joint - there is another one at the diff end, and lined up the 2 ends together. The rear end is small the than the front but may slide within it before it's welded up. With that I ran out of time before giving up for the day and coming to work.

So as a recap here's where i am right now:

1. Finish steering - wed up steering shaft, rack mounts. Re-cut threads on track control arms when die finally arrives from china. Assemble and test.

2. Recondition rear axle assembly - remove calipers and remaining flexi lines from BMW and install, along with connecting solid brake lines.

3. Install front brakes and plumb brakes - basic routing planned but mostly still to do. Front lines will be installed when engine is removed for step 4.

4. Modify propshaft and replace clutch - prop started, clutch just a normal service item, though new bolts will have to be sourced.

Once all these items have been achieved, I will have completed all the major mechaincal systems and the car will have full running gear, steering and brakes. Then i can get on with More interesting things!

Just a very quick update today. I have finally been able to remove the wheels from my BMW, so they will go up for sale on ebay shortly, hopefully raising some money towards buying the suspension. Removing them has also given me access to remove the rear claipers and flexi brake lines (if they are in good enough condition) which i will do on the next afternoon with good weather (snow forecast for tomorrow).

This afternoon I stripped down the auxiliary cooling fan from the beemer, soaked it in WD-40 and got it moving quite freely. By connecting the wiring directly to a spare battery (actually my booster pack) I was able to test it, and it spins fast and blows hard. So for now it's gone on the shelf with the other salvaged parts to await fitment.