|
|
|
08-08-2015, 09:35 PM | #1 |
Brigadier General
677
Rep 4,080
Posts |
Latest 1M conversion - splicing 1m flares approach
Featured on BIMMERPOST.com A few years ago switched from 335i to the 135i. Then I fell in love with the 1M. I considered getting the 1M, but lack of availability and the fact that the 1M is and instant classic that it better belongs in a garage then a Daily Driver I decided to go for it. Norcal sucks for shops willing to do extreme modifications, unlike Socal. And the cost for full quarter panel replacement was prohibitive without Insurance covering it. So after thinking about it I decided that I could probably do the conversion myself. A little about me. I don't have auto repair experience, but I've worked sheet metal as an aircraft mechanic. Using some of the same repair techniques I found a way to do it in a way that created a strong panel. The plan was to cut out the flares on the original 1M panels at the point they match the 135's then cutting out the 135 flares, flanging the edges and attaching with 3M panel bond and stainless counter sunk blind rivets. I know a few conversions have been done already, and the help from guys like IlikeBMXbikes and Venom has been huge, but I think this will be original in that it's the first Monaco Blue conversion and the first one done in a driveway. My full mods list: Brembo GT front brakes M3 Suspension conversion + Megan Adjustable Control arms M3 Strut brace Wavetrac LSD AST coilovers and Swift Springs Dinan Camber Plates Whiteline SFB AFE Intake COBB Tuning And what it looks like as a 135i: So here is a photo of the car before and after: Last edited by uberschnell; 08-29-2015 at 09:32 PM.. |
08-08-2015, 09:42 PM | #2 |
Brigadier General
677
Rep 4,080
Posts |
First stop was ordering parts. I managed to get the parts list together and ordered while prices were low.
Insane shipment, straight from Germany. Also picked up a hood. Seibon, and fitment was meh. Needed to do Aerolatches to get it to fit better. |
Appreciate
0
|
08-08-2015, 09:50 PM | #3 |
Brigadier General
677
Rep 4,080
Posts |
One of the best things about the 1M is the great selection of exhausts, so a full exhaust conversion was in order.
Always looking to cut costs, so I welded up some 3/8 rod for hangers. The 135i battery was too big, so I went with a smaller Interstate set up which saved me 20+ pounds. I had to weld up a new carrier for the battery, and it ended up working really well. |
Appreciate
0
|
08-09-2015, 04:27 AM | #4 |
Second Lieutenant
81
Rep 204
Posts |
nice, bring it to the treasure island cars and coffee!
__________________
Current: 2020 MB M2cs, 2022 G50 X5e, 2008 4Runner
Past: a91 ref blue Zupra, 86 Starion, 350z, Supra TT Auto, Supra TT 6 spd, IM/IM E46 M3, BMW 1m Coupe x2, S2000, 987.2 CS, ND2 MX5, LSB e46 M3 x2, 993 911 |
Appreciate
0
|
08-09-2015, 06:04 PM | #6 |
asn993
131
Rep 260
Posts |
Looking forward to your conversion.
It would be great if you could detail the steps from a DIY perspective. Plenty have shared the parts list which is awesome but for those who want to have a go at some of the bolt off bolt on parts some photo steps would be great. |
Appreciate
0
|
08-09-2015, 07:45 PM | #8 |
Colonel
376
Rep 2,388
Posts
Drives: M2 Competition
Join Date: May 2011
Location: East Bay, CA
|
Can't wait to see more of this!
|
Appreciate
0
|
08-10-2015, 08:20 PM | #9 | |
Brigadier General
677
Rep 4,080
Posts |
Quote:
I cut with the 3/8 overlap for the flange portion. Yes, those large containers have resulted in this Last edited by uberschnell; 08-10-2015 at 08:37 PM.. |
|
Appreciate
1
|
08-11-2015, 12:56 AM | #12 |
Banned
4143
Rep 6,924
Posts |
Nice project. This is actually how I would approach the rear conversion. I always thought it would be the most economical way. If you can get a clean cut, just butt weld the two. Spot/tack weld in intervals to not warp the panel. Then grind smooth.
|
Appreciate
1
|
08-11-2015, 08:43 AM | #13 |
Brigadier General
677
Rep 4,080
Posts |
I'm not going to weld, the metal is thin and warping is my concern, although I will do some spot welding on the edges. Instead I'm going to overlap the sheets by 3/8 and then flange the receiving side. I'll then use 3m panel bond along with 1/8 counter sunk stainless steel blind rivets to bond. It will actually be stronger then welding and wont have the same risk of rusting down the road.
|
Appreciate
1
|
08-11-2015, 10:52 AM | #14 |
1Addict
3424
Rep 8,045
Posts |
Been waiting since the original guys did this work for someone to do it this way. Best of luck to you, thanks for being the guinea pig!
__________________
Daily: E82 Mutt
Hauler: M57 Truck Looking for: 997/991 |
Appreciate
0
|
08-14-2015, 02:13 PM | #16 |
Brigadier General
677
Rep 4,080
Posts |
The big day. There is this funny feeling you get when you realize you are about to cut up a perfectly good car. The answer was to drill a hole in the side of the car, now I couldn't back out.
On to the great news; My measurements were right on. This shows that the 135i and the 1m fenders begin to flare at the same place, only the 1m flares continue on to a more extreme curve where the 135i flares flatten out. For example, the gas cap door in the 135i and the 1m are the exact same profile until about 3 inches below the door, where the 1m flares out more. The skirts and the bumper are lining up perfectly. Based on this I believe it would be easy to create fiberglass molds of the 1m quarter panels that would then line up perfectly on a 135i. Hope this is some help to someone out there. |
Appreciate
0
|
08-14-2015, 02:21 PM | #17 |
Brigadier General
677
Rep 4,080
Posts |
The combo of panel bond and rivets made for an extremely strong and rust proof bond. There is a slight transition between the flare and the panel. A little sanding and bondo will make quick work of that.
|
Appreciate
0
|
08-14-2015, 02:28 PM | #18 |
Brigadier General
677
Rep 4,080
Posts |
I found a body shop in Belmont that will do quality custom work and at very reasonable price. I outsourced the finishing work and paint.
Last edited by uberschnell; 08-14-2015 at 02:39 PM.. |
Appreciate
0
|
08-14-2015, 05:19 PM | #22 |
Colonel
1387
Rep 2,136
Posts
Drives: '11 135i M Sport
Join Date: Dec 2013
Location: Delmarva Peninsula
|
Welp now I know how I'm doing my rear arches. Fantastic work and research.
How about the inner wheel well? How are you extending that? Or did the body shop take it from there?
__________________
|
Appreciate
0
|
Post Reply |
Bookmarks |
|
|