Project E34 535i Restoration

[Bogracer]

Brought this great 535i after two years of looking for something that was good enough, most being terribly neglected to death, intergalactic mileage or 'maxed' examples – and I wanted a rare manual. Even though this is pretty much a one owner, low mileage, rot free car it needs a total refresh and a sympathetic restoration to get back the 'as new' sharp driving feel.

The car made the trip back from Glasgow to Birmingham, I had a flask of tea just in case I was dumped on the hard shoulder. No problem, it just wafted back. Except it was a nice day and I opened the sun roof and this stuck open. Luckily it did not rain.

According to the DVLA there are only 21 manual 535i's left on the road, it's amazing how the numbers slip away to be track warriors or broken up and splattered across EBAY. Oh and quite a few RHD's 'dual control' cars were used in the film 'Ronin' as stunt doubles along with M5's.

1st job take the sunroof apart, clean lubricate and put back together. Done.

Edited by Bogracer on Tuesday 22 November 11:38

Edited by Bogracer on Tuesday 22 November 11:43

[Bogracer]

Step one – a detailed survey of the car, so up on the ramps and write a big list. You name it, were replacing it for fresh OEM BMW or better, no cheap replica parts, and a full Bosch diagnostics and Inspection 2 service and replaced all the fluids including the gearbox. No error codes.

Edited by Bogracer on Tuesday 22 November 11:32

[Bogracer]

Just brought a LSD, I think is essential on a 535i or anything sporting.
Having it rebuilt with new clutches, seals and bearings.

I don't know about you but when Steve McQueen does a 'burn out' in his 390 Mustang in the film Bullitt, I always think how mean not to have an LSD or anti-tramp bars as one wheel spins away, leaving a single black line down the road? It perhaps explains why there was no drifting in the film.

But hey I love the film anyway.

[Bogracer]

Completing the service history, checking the DVLA MOT database, since 2006 the car has only covered 4000 miles, corroborating the story that the owner emigrated leaving the car in his garage for occasional use.

Edited by Bogracer on Tuesday 22 November 22:03

[Bogracer]

Budleigh said:

Nice project. What's the interior like?

The car has been garaged all of its life so the interior is in great shape, no fading or cracking.
Just needing a really deep clean and the leather conditioning.

I am on the look our for some grey rear door panels though as these have detached and the owner though it was a good idea to stick screws through them!
The rear parcel shelf the fabric covering has started to detach. This will all be addressed.

[Bogracer]

Waynester said:

Nice, good luck with it. Looks a good one

Agree with your statement about 'loads of em about, now so few'

One day soon(ish) we will be saying the same about the E39!

Yes we live in disposable society, but hey we would never move forward if we all kept our cars and never upgraded.

[Bogracer]

I think the 535i E34 is worth it and I want a car that drives fantastically.
I want a standard looking car that has the best possible running gear.

Suspension, suspension, suspension improving but maintaining a pure E34 535i experience.

I am working with Bilstien in Germany to develop a custom suspension set up for 'fast road' rather than 'harsh' race track set up, which is pretty terrible on the road or Nurburgring! – lowering about 20 to 30 mm, thicker anti-roll bars. So, it still cossets and at the same time is slick through the windy bits.

Custom dampers and spring ratings which will be bespoke made to spec in Germany, taking some good advice from my friend 'world famous' Roddy Harvey Bailey, who works for most of the car companies as a handling and dynamics consultant.

Don't ask the cost!

Edited by Bogracer on Wednesday 23 November 11:02

[Bogracer]

I think I am going to go for Aeroquip instead of standard rubber flexi-hoses as they will give a stronger peddle and well it's a bloke thing they look better. Might do the same for the fuel line.

[Bogracer]

The bill has broken the £5000 barrier and still going!

I sat in the BMW main agent about to sign for an order for 640d, so as soon as you drive out of the show room you loose £10,000? It's a lovely car but I had a moment of clarity. Why not save something, why not have something a bit more unique, a classic that is totally useable?

I think my friends think I have lost the plot, but it give you a nice warm feeling.

[Bogracer]

Stripping and renewing the cooling system, which is fine but needs checking over, so new hoses, new radiator, new water pump, new viscous coupling, new thermostat and sensors.

Peace of mind and all that.

[Bogracer]

Fitted new enamel wheel badges last night as these had corroded to dust.
The wheels are immaculate an original so back to perfect.

It's the little things.

[Bogracer]

Jobbo said:

Crikey, that looks a lovely example in the first pics; how much of what you are doing is required and how much is just because you can?

I have fettled many cars and one thing I have learnt is while you have things apart do the lot in one go, it saves you much pain in the long run. It's a good example but everything is nearly 20 years old and the cost is not huge especially when compare the costs against depreciation on a newer car. Also, it takes the car from a good example to an excellent example with no question marks over what might fail next? Nothing. It's all been checked and replaced. And you have a car drives well, better than new. Plus, it's just the fun of doing it, isn't it?

[Bogracer]

formautomotive said:

Great to see some care taken, We have a 535i in the family since my grandparents bought new. shame its a auto, I changed the headgasket 2 years ago and ran fine, started running bad again last week changed rotor arm and cap I honestly can say it drives like new. A manwel conversion would have to be done if i take care of it later on in its life.

Simon @ www.formautomotive.co.uk

I have owned many BMW's, new and old and the 535i is a gem. Watch the rust, ramps, wire brush and Waxoil.

[Bogracer]

It's a good outlet for my OCD!

[Bogracer]

bm0p700f said:

21 RHD manual 535i left - what!

I checked again with "how many left" it's now 116 manual 535i and 146 manual sports. See what you mean

[Bogracer]

I will get some more photos up when I get stuck into the work again chaps.

[Bogracer]

E38Ross said:

keep up the cracking work, and as others have said....photos please!

have driven a 535i (SE spec) manual with around 230k miles on the clock, it was still something to behold. lovely cars and properly built to last!

There are 535i's in the US with over 500,000 miles on the clock! The M30 3.5 engine is charismatic and tough, with loads of heritage and DNA going back 50+ years.

[Bogracer]

More surveying photographs, the car was very dusty underneath and most of the issues were age related rather than wear.

Any rust being superficial, I must have checked over 10+ E34's most looking good until you prod and the screw driver goes right though. The usual story of cracking under-seal and water festering underneath.

Old under-seal being removed and a proper 2 day session of professional rust proofing.
Nothing here fails the MOT surprisingly, but in 150 MPH car, it is a little unnerving so everything is being replaced.

[Bogracer]

Compression testing the engine revealed no loss of compression, so every cylinder is in rude health.

[Bogracer]

Vroomer said:

I had one of the very first E34s. Took delivery of a manual 535i in August 1988. Everyone else seemed to be ordering autos.

It was a superb car. I sold it in 1993 with 120k on the clock. Still looked and drove like new.

After a couple of years I got letter from a guy who'd just bought it and wondered if I had any history. I sent him a pic of it on delivery day plus more details.

Got a reply from him saying he was gutted. The car had 65k on the clock. In reality must have done 150k by then – but this shows how tough the cars were if a rogue could shave nearly 100k off and get away with it!

Yes, there were loads of ads for mileage adjustment with the arrival of digital odometers! A clockers dream indeed, easy to hide a 100k in the engineering.

I traced and confirmed the history through the BMW dealer network, and old MOTs through the DVLA, early in its life it covered normal yearly mileage, the chap who owned in worked mainly abroad, one year it only did only 100 miles between MOT's! Advisories and fails are logged and the fails were for mainly corroded brake disks.