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E36/7 Z3 (1996-2002)
E36/7 Z3 Roadster, Z3 coupe, Z3 M Roadster and Z3 M Coupe talk with our gurus here.

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  #1  
Old 06-02-2004, 11:22 AM
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Randy Forbes Randy Forbes is offline
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99 ///M Rdstr trunkfloor repair...

I took the car in yesterday and met with the body mechanic this morning. He wanted to know what I wanted done, so the Service Manager asked me to meet with him.

BMWNA's suggestion to replace the entire trunkfloor panel made me a little nervous. If they had devised an entire new assembly that addressed the weakness of the original, that would be a different story...

Cutting an otherwise good car in (nearly) half to wind up with a car that was no stronger than it left the factory five years ago does not seem like the right solution to me. I don't want to repeat this again, not with the same car anyway! I will be repeating the process again with the other car as soon as this one is done and passes judgement.

It has been determined to not section in the entire assembly, but to repair the (albeit minor) damage and strenghten the area using the pieces laying in the trunk.

Picture me taking a big sigh of relief!

Those pieces laying in the trunk will be utilized to strengthen the xmbr as described here

Here are a few pictures that show how big the Z3's trunk is when it's not in the car.
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1957 Austin-Healey 100/6 Wine Red
1961 McCulloch R1 go-kart Screaming Yellow
1995///M3 Coupe Dakar Yellow Eurosport Twinscrew S/C
1999///M Rdstr Cosmos Black Eurosport Twinscrew S/C
1999///M Coupe Estoril Blue Eurosport Twinscrew S/C
2001///M Rdstr Steel Gray
2011 X5 35i Sport Deep Sea Blue/Cinnamon

Last edited by Randy Forbes; 06-11-2004 at 03:43 PM.
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  #2  
Old 06-02-2004, 05:40 PM
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I echo the big sigh of relief!

Tht did NOT sound like a good way to fix things.
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  #3  
Old 06-11-2004, 03:37 PM
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Randy Forbes Randy Forbes is offline
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Not much to report for the past week (judging by the activity of this thread, not likely a problem ).

I stopped by yesterday and the car is "almost" apart; all the trunk trim has been removed and the bumper and tailights were also removed to save them from damage while the work takes place.

They still have to drop the subframe, not so much for their repair operation, but as a favor for me to be able to pull out the old subframe bushings and replace them with the Ireland ones. You've got to love that kind of cooperation

They also discovered that the differential mounting ear was starting to crack (remember that this car was only autocrossed just a handful of times and never by Sue).

Just a couple shots that show the naked trunk before work commences.
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1957 Austin-Healey 100/6 Wine Red
1961 McCulloch R1 go-kart Screaming Yellow
1995///M3 Coupe Dakar Yellow Eurosport Twinscrew S/C
1999///M Rdstr Cosmos Black Eurosport Twinscrew S/C
1999///M Coupe Estoril Blue Eurosport Twinscrew S/C
2001///M Rdstr Steel Gray
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  #4  
Old 06-12-2004, 09:48 AM
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Randy,

Is BMWNA covering the cost? Who is doing the work?

Nice Healey! Did you go to the annual British car show at Easton?
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  #5  
Old 06-12-2004, 03:50 PM
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Randy
Your email must have problems, BMW NA forwarded this to be to get it to you

Dear Randy Forbes:
I am Edward Longshanks with bmwna, We have figured out that the use of your hardtop is possibly the cause of your sub frame problem, I am pleased to let you know that a remedy had been found. It was staring us all in the face the whole time. All that is needed to be done to keep this from happening again is to ship your hardtop to san antonio and we will take it from there. thank you for your time and safe driving
E. Longshanks
Senior Director of Lets get Max a Hardtop
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  #6  
Old 06-13-2004, 08:37 AM
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bob lindquist bob lindquist is offline
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I am right I saying no pieces of the trunk floor section BMW sent are being used in the repair?


Only the pieces you devised.
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  #7  
Old 06-13-2004, 12:06 PM
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Randy Forbes Randy Forbes is offline
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Quote:
Originally Posted by bob lindquist
I am right I saying no pieces of the trunk floor section BMW sent are being used in the repair?
No, for it to be a legitimate section, they have to use a portion of the trunkfloor assembly.

I can give you more details at HC...
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1957 Austin-Healey 100/6 Wine Red
1961 McCulloch R1 go-kart Screaming Yellow
1995///M3 Coupe Dakar Yellow Eurosport Twinscrew S/C
1999///M Rdstr Cosmos Black Eurosport Twinscrew S/C
1999///M Coupe Estoril Blue Eurosport Twinscrew S/C
2001///M Rdstr Steel Gray
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  #8  
Old 06-13-2004, 08:46 AM
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bob lindquist bob lindquist is offline
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shouldn't we be looking at adding this also?
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  #9  
Old 06-13-2004, 10:38 AM
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Who was it that welded on a second ear to the diff housing? He had the black coupe at the fix it day.
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  #10  
Old 06-13-2004, 12:10 PM
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Randy Forbes Randy Forbes is offline
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Quote:
Originally Posted by Mpire
Who was it that welded on a second ear to the diff housing? He had the black coupe at the fix it day.
There're actually a few of them out there (that I know of). I have a picture and a link to Mr. Blonde's Coupe in one of my other threads on this subject.
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1957 Austin-Healey 100/6 Wine Red
1961 McCulloch R1 go-kart Screaming Yellow
1995///M3 Coupe Dakar Yellow Eurosport Twinscrew S/C
1999///M Rdstr Cosmos Black Eurosport Twinscrew S/C
1999///M Coupe Estoril Blue Eurosport Twinscrew S/C
2001///M Rdstr Steel Gray
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  #11  
Old 06-13-2004, 09:14 PM
MCoupeD MCoupeD is offline
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Randy,

YOU ARE AMAZING!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!

Respectfully,
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  #12  
Old 06-14-2004, 08:15 AM
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Quote:
Originally Posted by Mpire
Who was it that welded on a second ear to the diff housing? He had the black coupe at the fix it day.
Brent - that was Duane Ball, aka 8ball. He rarely posts because of his dialup speeds, but you can occasionally find him on roadfly.
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  #13  
Old 06-17-2004, 11:22 AM
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Randy Forbes Randy Forbes is offline
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Bodyshop manager called me up yesterday evening and said I should come by for a "Kodak moment".

Armed with a box of fresh donuts, I showed up first thing this morning to get a few more shots of the progress.
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Randy Forbes
1957 Austin-Healey 100/6 Wine Red
1961 McCulloch R1 go-kart Screaming Yellow
1995///M3 Coupe Dakar Yellow Eurosport Twinscrew S/C
1999///M Rdstr Cosmos Black Eurosport Twinscrew S/C
1999///M Coupe Estoril Blue Eurosport Twinscrew S/C
2001///M Rdstr Steel Gray
2011 X5 35i Sport Deep Sea Blue/Cinnamon
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  #14  
Old 06-17-2004, 04:31 PM
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Randy Forbes Randy Forbes is offline
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Stopped back by again this afternoon to see how things went and got a couple more pictures.

These pictures show the differential mounting ear that was modified by overlaying a second stamping on top of the original to double the wall thickness.

The tech was proud of the fact that you have to really look close to see the difference. When the job is finished, it's important to him that it looks "factory". My kind of guy!
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Randy Forbes
1957 Austin-Healey 100/6 Wine Red
1961 McCulloch R1 go-kart Screaming Yellow
1995///M3 Coupe Dakar Yellow Eurosport Twinscrew S/C
1999///M Rdstr Cosmos Black Eurosport Twinscrew S/C
1999///M Coupe Estoril Blue Eurosport Twinscrew S/C
2001///M Rdstr Steel Gray
2011 X5 35i Sport Deep Sea Blue/Cinnamon
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  #15  
Old 06-13-2004, 12:07 PM
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Randy Forbes Randy Forbes is offline
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Quote:
Originally Posted by bob lindquist
shouldn't we be looking at adding this also?
I was going to bring that up when the gray car goes in...
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1957 Austin-Healey 100/6 Wine Red
1961 McCulloch R1 go-kart Screaming Yellow
1995///M3 Coupe Dakar Yellow Eurosport Twinscrew S/C
1999///M Rdstr Cosmos Black Eurosport Twinscrew S/C
1999///M Coupe Estoril Blue Eurosport Twinscrew S/C
2001///M Rdstr Steel Gray
2011 X5 35i Sport Deep Sea Blue/Cinnamon
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  #16  
Old 06-17-2004, 09:01 PM
Razorbak Razorbak is offline
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Quote:
Originally Posted by Randy Forbes
Here are a few pictures that show how big the Z3's trunk is when it's not in the car.
Randy, amazing pics! Is that your trunk in the pics on the floor (first post), or is that from a stand-alone mockup or another car? If it's yours, how did they get it out of the car?

I'm curious to hear a description of the access and removal process. This reminds me of Boyd Coddington's shop on American Hot Rod (Discovery Channel, Friday nights). Fortunately for you, Bluebear is not lurking in the corner shooting paintballs at the other shop employees.

Last edited by Razorbak; 06-17-2004 at 09:04 PM.
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  #17  
Old 06-17-2004, 09:52 PM
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Randy Forbes Randy Forbes is offline
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Quote:
Originally Posted by Razorbak
Randy, amazing pics! Is that your trunk in the pics on the floor (first post), or is that from a stand-alone mockup or another car? If it's yours, how did they get it out of the car?
The picture shows a brand new replacement trunkfloor assembly, courtesy of BMWNA. A portion of which will be used in the repair of the black car.

Stay tuned for continued coverage...
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1957 Austin-Healey 100/6 Wine Red
1961 McCulloch R1 go-kart Screaming Yellow
1995///M3 Coupe Dakar Yellow Eurosport Twinscrew S/C
1999///M Rdstr Cosmos Black Eurosport Twinscrew S/C
1999///M Coupe Estoril Blue Eurosport Twinscrew S/C
2001///M Rdstr Steel Gray
2011 X5 35i Sport Deep Sea Blue/Cinnamon
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  #18  
Old 06-24-2004, 08:00 AM
TooManyIDs TooManyIDs is offline
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Quote:
Originally Posted by Randy Forbes
The picture shows a brand new replacement trunkfloor assembly, courtesy of BMWNA....
I missed the history on this. Assuming your car is out of warranty, what did it take for BMW to cover this repair?
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  #19  
Old 06-24-2004, 08:24 AM
TooManyIDs TooManyIDs is offline
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Quote:
Originally Posted by TooManyIDs
I missed the history on this. Assuming your car is out of warranty, what did it take for BMW to cover this repair?
Found it.

Quote:
Originally Posted by Randy Forbes
Got the word yesterday (4/27/2004) that BMWNA approved the trunk floor replacement on both cars.

Parts have been ordered, when they come in I'll grab some pictures before the work starts.

If they don't bar the doors, I'll take more pictures as the work progresses.

Now that the weather is getting nice again, what better time to take the car(s) off the road...?

Black car is first in line!
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  #20  
Old 06-24-2004, 09:05 AM
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Randy Forbes Randy Forbes is offline
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Quote:
Originally Posted by TooManyIDs
I missed the history on this. Assuming your car is out of warranty, what did it take for BMW to cover this repair?
Al,

A little sidenote about how this all came to be...

I first noticed the problem of the floor (in the gray car) after Yianni posted a picture of his Coupe with what looked like an 1-1/2" gap in his trunkfloor. Most of us were already aware of the differential mount cracking, and I monitored it regularly. When the trunkfloor issue surfaced, I was taken by surspise! I checked both cars and found the earliest signs of separation (any less damage and I wouldn't have seen it at all).

I showed the gray car to the service advisor at my dealership and said he'd have to call in the area rep. In the meantime, I took a good look at the black car too and found it was slightly worse than the gray one. When the area rep came to town we showed up with both cars. The rep spent about an hour on each car, taking pictures and conferring with the bodyshop manager. Eventually, the work was approved by BMWNA.

There was no mention of warranty, or lack of, on the black car (a 1999 model).

Here's the "discovery" thread: http://www.bimmerfest.com/forums/showthread.php?t=55752
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1957 Austin-Healey 100/6 Wine Red
1961 McCulloch R1 go-kart Screaming Yellow
1995///M3 Coupe Dakar Yellow Eurosport Twinscrew S/C
1999///M Rdstr Cosmos Black Eurosport Twinscrew S/C
1999///M Coupe Estoril Blue Eurosport Twinscrew S/C
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  #21  
Old 06-24-2004, 01:23 PM
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dwaynemosley dwaynemosley is offline
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What did you guys use to remove the insulation stuff glued to the floor of the trunk/rear hatch area? I've got a few light splits in my insulation, but don't want to tear it all to hell trying to determine if I've got the floor separation problem.

Thanks,
Dwayne
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Old 06-25-2004, 07:33 AM
TooManyIDs TooManyIDs is offline
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Quote:
Originally Posted by Randy Forbes
Al,

A little sidenote about how this all came to be...

I first noticed the problem of the floor (in the gray car) after Yianni posted a picture of his Coupe with what looked like an 1-1/2" gap in his trunkfloor. Most of us were already aware of the differential mount cracking, and I monitored it regularly. When the trunkfloor issue surfaced, I was taken by surspise! I checked both cars and found the earliest signs of separation (any less damage and I wouldn't have seen it at all).

I showed the gray car to the service advisor at my dealership and said he'd have to call in the area rep. In the meantime, I took a good look at the black car too and found it was slightly worse than the gray one. When the area rep came to town we showed up with both cars. The rep spent about an hour on each car, taking pictures and conferring with the bodyshop manager. Eventually, the work was approved by BMWNA.

There was no mention of warranty, or lack of, on the black car (a 1999 model).

Here's the "discovery" thread: http://www.bimmerfest.com/forums/showthread.php?t=55752
Randy, thanks. It's all enough to keep me from considering a Z3. I only hope this doesn't extend to the 3 series or Z4?

I'm guessing that not all others will find as willing a dealer. I hope I'm wrong or this will prove to be a mess for Z3 owners.
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  #23  
Old 06-18-2004, 05:06 PM
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bob lindquist bob lindquist is offline
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so you cut out the cross member to add INSIDE the hollow an additional plate.
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Dinan suspension, M rotors /Axxis pads
Eurosport Cam Kit 1, touch lane change
Zaino polish, Beach Sand
Garys mirror adapter, S54 Oil Cooler
seat tilt coupling nuts, spare tire

"life's to short to drink cheap beer"


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  #24  
Old 06-18-2004, 06:54 PM
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Randy Forbes Randy Forbes is offline
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Quote:
Originally Posted by bob lindquist
so you cut out the cross member to add INSIDE the hollow an additional plate.
Kind of...

The xmbr wasn't cut, the floor section above it was cut out to get access to the inside of the xmbr.

He still has the vertical membrane to install and then he'll finish it off with the piece I made. See below:

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1957 Austin-Healey 100/6 Wine Red
1961 McCulloch R1 go-kart Screaming Yellow
1995///M3 Coupe Dakar Yellow Eurosport Twinscrew S/C
1999///M Rdstr Cosmos Black Eurosport Twinscrew S/C
1999///M Coupe Estoril Blue Eurosport Twinscrew S/C
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2011 X5 35i Sport Deep Sea Blue/Cinnamon
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  #25  
Old 06-21-2004, 05:25 PM
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Randy Forbes Randy Forbes is offline
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Only needs to be put back together now. They'll work on other jobs while I continue to wait on the Ireland bushings (called them again today...).
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1957 Austin-Healey 100/6 Wine Red
1961 McCulloch R1 go-kart Screaming Yellow
1995///M3 Coupe Dakar Yellow Eurosport Twinscrew S/C
1999///M Rdstr Cosmos Black Eurosport Twinscrew S/C
1999///M Coupe Estoril Blue Eurosport Twinscrew S/C
2001///M Rdstr Steel Gray
2011 X5 35i Sport Deep Sea Blue/Cinnamon
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