GETTING A BIT TOO FAR OVER THE SKIS
I try, sometimes successfully, to have a theme for every post here. The last post, When good enough isn’t good enough, was about re-repairing things in anticipation of Legends of the Autobahn 2024 and also bringing the restoration up to a new standard. In doing so, it seems, I got a bit ahead of my skis.
Getting ahead of my skis is something I try not to do. And usually it’s easy to accomplish: just don’t write about anything until it’s finished, after I know the full arc of the story. But I violated that rule last month when I wrote, among other things, about the fix to the flickering oil pressure gauge and having the body shop replace the transmission speedo gear so I’d have a functioning speedometer and fixing the previously addressed rust in the frame-rail. None of those worked out as planned and the story arc changed things in big and small ways.
Even though I had dropped the Alpina off at the body shop well in advance of LoTA they didn’t have time to fix the frame-rail. And that was disappointing but understandable: they had at least one other car in there being prepped for LoTA and several, you know, getting repaired. Conversely, the frame-rail was an optional project, not nearly as mission critical as other things on their plate, like trying to get another very nice e21 323i together for Monterey.

Although this is not the body shop’s fault, the first thing I noticed upon driving it home was that the speedo gear change did not fix the non-functioning speedometer. I spent the drive strategizing how to fix that and the stumbling on acceleration. Before this revelation I planned to ship the car to my new home in New York and, over the winter, becoming proficient enough in K-Jet fuel injection to fix the stumbling/lean running myself. I unsuccessfully tried this in the 1990s when I owned my first e21 323i but was determined to do better this time. The transmission, however, added a new wrinkle. So, I hatched a new plan to take the car to Sacramento and have Stu, who worked on the transmission before it was put in, fix the speedo drive. And he also happens to be the best person I knew for fine tuning the K-Jet. To make things even better, another friend drilled and tapped a spare fuel pressure regulator to make it adjustable. A phone call to Stu and a plan was made.
Once I got the car home, my first mission was to change the oil pressure sender. You may recall, I figured out that I had put in a 80 PSI sender in the car but was using a 150 PSI gauge. I put the new 150 PSI gauge in but noticed, when taking the old one out, that it was not an 80 PSI sender, but the same as the new one I was installing. To add insult to injury, once the oil was warm, the idiot light still flickered. Also, the pressure never gets above 60 PSI when cold or 45 when warm. All this isn’t dangerous—more just annoying and perplexing, as ever M10 I’ve built hovers around 60 PSI when warm and 90 when cold. I’ll get to the bottom of this but will wait to explain the fix (or should I say anticipated fix) because I don’t want to again get too far over my skis.
Other than the lack of speedo and flickering oil pressure light, the drive to and from Legends was uneventful and the show was a lot of fun. I spent most my time talking to folks. I knew several of the participants, some who were pretty good friends, and walked around socializing most of the day. I saw Julius who owns a e21 B6 (but not running well enough to bring to Legends), Ricardo who is restoring and modifying his e21 (and got to meet his son who is going to my alma mater), Rob who owns several 2002s but was having his 2002tii with many Alpina bits (including an A4 injection system) judged in the concourse, and many 2002 friends (Jan, Bart, Delia, etc.) and some new friends. And, of course, the Alpina crowd, too. Because of all the socializing I didn’t really have a chance to take many—ok, any—pictures but I was able to harvest a few cool ones from the BMWCCA Golden Gate chapter FaceBook page and other such places. It was a bitter-sweet Legends for me, given that I’m moving away: It was great to see so many folks I know, some well and others car acquaintances. But I worried about how long it would take to make the same sort of connections on the east coast. Of course, I could always avoid the August humidity of the east coast and make Legends an annual trip to California….


After a day of rest, I got up early Saturday morning to take the Alpina up to Sacramento. By the time I got to San Francisco, where I stopped to fill the car up with gas, it was drizzling. Apparently, the tires didn’t like that as I accelerated up the cloverleaf back onto the highway and the rear end came around. In the spin, the car jumped a curb. After the visual inspection everything seemed fine and I was back on my way. A few miles later, however, some unusual noise was coming from the front and steering required more effort. I got off the highway and confirmed my suspicions: a flat tire. Luckly, I recently got a used wheel with decent looked rubber. I called AAA; there was a truck minutes away, the spare was installed, and I was back on my way!


Apparently, the good rubber was really old and rotten. With no usable spare, I called AAA; almost 90 minutes later, the truck showed up and towed me to the shop. Stu then took me to the train, which I took home. I wasn’t happy about how the trip turned out but I was thankful that I didn’t have a blow out with the disintegrating spare and that the spin didn’t appear to cause any more damage than a flat tire.

So, the car is in Sacramento, back in Stu’s hands. When I get it shipped east I’m hopeful that the speedo will work and the fuel injection is dialed-in. And I’ll work on the that flickering oil pressure light. But I won’t get out over my skis and declare any of these things fixed!


Then I drove the car up to Santa Rosa and dropped it off at North Bay Bavarian. The did a bunch of stuff that was above my paygrade. They put in an adjustable suspension, both front and rear, to get rid of some the excessive camber and caster.






Once installed the oil pressure gauge was vexing me. The idiot light would flicker on idle and the pressure seemed low, around 30-40 PSI. After a bit of troubleshooting, I realized that I used an old sender I had left over from another project and that was a 0-80 PSI gauge whereas I was using a 1-150 gauge. The new sender is on order and the problem should soon be solved.













The last bit of redoing is in progress. The car is back at the auto body shop to correctly fix the rust that we ground out and covered up. While the prior repair was sufficient, it is ugly and there is a possibility that the rust will come back. The body shop will grind it all out and weld in new metal within the frame rail correctly. It will look factory and be fitting of what this car has morphed into.


While in the body shop, the 3.22 Limited slip differential will be installed and a new (used) speedo gear in the transmission–so hopefully the speedometer will work. The new diff will lower the revs at freeway speeds and make the drive down to Monterey a bit more pleasant.





Once at home, I put in the heater control panel (not hooked up, but at least there’s not a big hole in the middle of the dash!), tried to run down the short grounding out the gas gauge (no success), swapped in my extra speedo to see if that cured the problem (it didn’t; likely the speedo cable or the fitting at the transmission), cleaned up wiring issues under the dash, attended to many, many little details, and tried to straighten the off kilter steering wheel.


















So I tinkered. I took off the electrical tape someone installed in a fit of ugliness and re-wrapped the wiring harness with new cloth tape.
I take out the old, non-functional antenna and put in a new one (forget that there was no center console, let alone stereo in the car).
I traced down extra and errant wiring, cleaning messes in the engine compartment and under the dash.

Several little parts were added, like the leaf guards in the hood.

And, I did the one thing that is fairly easy yet yields big results and nice money shots: installed the freshly recovered seats in the blingy Alpina cloth.

Other little things like cleaning the carpet, and rewiring the Hella big/little headlights helped move things along.
But then Summer became Fall and things stalled to a crawl, mostly due to festering frustration. Why was I frustrated? Heater problems. No, not the garage wasn’t heated. Rather, the problem was the heater in the car; specifically, my tinkering under the dash revealed that the heater ducting was removed along with the dash when it was taken out some 5 years ago (to have the cracks repaired); when the body shop reinstalled the dash they forgot to put the heater ducting back in first.
defroster ducting as shown in the parts “book”
heater ducting as shown in parts “book”
They aren’t finished, in fact they pretty much just started. They get to my car in between their regular work; I’m in no rush and they aren’t either, really. But they got it started and are making the progress that I couldn’t. They also found that the brakes are acting up and it may need a new booster or master cylinder. For me, just hearing it run was great. I’m an amateur motor assembler and worry about I did wrong until the thing runs without grenading. We’ve crossed that line, so I guess I didn’t fuck anything up too much.
Getting the sunroof back in was not easy. The entire mechanics were disassembled and most of the little parts did not stay with the shell when the body shop closed. Sourcing those small but necessary parts takes time and ingenuity. Some parts were available from BMW, some were on eBay new or used, some we got from a junk yard with an old 6-series (thankfully BMW used the same parts in several different platforms). That took many trips up to Sacramento to install the parts I got and figure out the ones I needed to get. Slow and frustrating progress.
Above I told you the sunroof was in. And that is true. But it was a misleading but factual statement (my lawyer training coming through!). We finally got all the parts and were able to put the sunroof in the car. But we couldn’t get it operating. Or at least fully operating. The tilt works but not the back and forth. I’m sure with time and energy it will work but I was up for two days and had other things to accomplish before leaving. Plus, I really don’t like sunroofs anyway, so having it in but not working is not anything even near a hardship for me. Finally, the sunroof and the hood were the two final steps in getting the car water tight so it could be trucked back home.













Rear windows put in and parts for door trim being sourced from around the world.
And, most recently, the sunroof is finally being addressed. First was cleaning up the sunroof frame and installing the headliner on it. Next up will be reinstalling the sunroof mechanics, the headliner frame and then the roof itself. That may happened next week.





But there’s plenty to still be done. The interior still needs work: There are no seats, the dash has not been populated and lots of little parts are surely missing or broken, including the heater control unit. But that can wait until after we confirm that the car will actually run. To get there, I have a ton of details that need attention: wire in the coil (replaced by an MSD by a previous owner); finish other electric details, like sourcing and attaching battery leads; and plumb in the rest of the fuel delivery system.