#ZedShed From Rust to Roadster: The HI KTY Z3 Revival

[Lee]

Finally the Shed team have started getting their ducks in a row, we decided to kick things off slowly with a lovely Auto 1.9 build, owned by @MuttyMax I believe his daughter will be driving this once complete.

After nearly a year in storage we had to fight the spiders to get her out.

some real nice goodies bolted onto this old girl

booty shot

more Schnitzer!

Lovely spec for a 1.9, low milage and in all round great condition.

extended leather

very clean bay

never seen this before.

ready to lift

under side is very tidy, all very surface.

beam bushes goosed, shouldn’t be sat on the plate

can see some genuine BMW tank straps.

some other observations, all the tyres need replacing, one is 20 years old, with 3 different brands.

47th week of 2005.

lots of cracks.

The ramp decided to break after this. So once she’s fixed we’ll be making a start on her in the coming weeks. Many parts to fit!

watch this space.

 

[Kai]

Looking forward to winter to bring my Z’ed again

 

[MuttyMax]

New wheels and tyres already sourced as well as some.genuine new schnitzer spings for the 1.9 (previously advertised on the forum).

 

[Lee]

We smashed it for day one. Now the ramp had been repaired and no longer likely to throw a car at me we all got stuck into it.

First task that threw a spanner in the works was the exhaust manifold, 3/4 studs decided to snap. No amount of heat was going to free these.

As always I keep forgetting to take more photos, any volunteers to take photos for us

Two hours in and the subframe was down

Underside very muddy

normal shot bushes.

then later on pressed out.

a lot of surface rust, little wear on the disc but heavy surface wear

we had a full house today. Many came down to say hi.

rear end stripped. Removed all items ready for powder coat. First set of wheel bearing done this year, we all forgot how tough they are to remove.

pile forming

front end also mostly stripped. Getting there already.

 

[Lee]

Been a crazy 3 days. Found out what the extra oil cooler was feeding. It cools the oil for the autobox.

Also removed all the arch liners to inspect the metal work.

bung removed

also needed to remove the last of the front hardware

didn’t take long and all for the bin.

engine now hanging from the beam

old engine mounts and front subframe ready for coating.

After a days worth of stripping parts I got everything over to the coaters. Everything is going to be blasted, Zinc and Matt black.

now we clean things up and wait.

 

[MuttyMax]

And I find new wheels …

 

[Lee]

That’s really annoying. Luckily many nice wheels to choose from. I’m shocked they stole the wheels and left the tyres.

This 1.9 though, if o didn’t know any better I would think it’s been used off road. I’ve had to sweep up so much mud.

 

[MuttyMax]

Humm ....... wondering who's had the keys to this for x months when I've been overseas then? Lee the rally guru ....

 

[Lee]

Nice big juicy update. I got the powdercoat back really quickly so today I built the majority of the front end back together.

first job is always the front subframe,

bolted up

next up wishbones.

really like the Matt finish on this powder coat.

new mounts looking fresh

assembled the front shocks with the Genuine Schnitzer springs.

way too clean this.

The little bits all came up well

got the beam bushes in

front end now waiting for a few final bits. Also a few bushes left to arrive for the rear.

 

[Mint]

Great work Lee, as usual

 

[IanA]

Great work Lee, as usual

+1 from me.

I was there for the rear end stripdown and it was impressive to see a team of people who know how to do it rip through it so quickly.

My 2.0 is in the queue for a rear end rebuild and new clutch after a hiatus incuding some work on manifold bolts. I've split and sleeved the pipes just before the cats to make the exhaust removal easy for the ZedShed guys.

 

[Lee]

Been struggling with parts for this build so it stalled last week. Luckily today I got to mostly build the rear and tomorrow we’ll be fitting.

Diff got a clean and paint along with new bush

Started building the arms, bearing went in a lot easier than it came out

backing plate on along with shoes

down on along with brackets n ABS sensor

looking smart all together

letting the diff dry overnight and the last thing is waiting on the brakes to come back from paint.

 

[spurs fan in a coupe]

Looks like new

 

[IanA]

Having visited the ZedShed a few times and seen rear suspension stripdowns I've always been (pleasantly) surprised at the ease with which the guys (and gal) loosen the various fasteners. It bodes well for my 2.0 when its turn comes. Heat is applied and then the relevant spanner/wrench does the job. When I mentioned this to Lee he said it was all down to the enhanced tensile strength of the bolts that BMW use.

I've just found this table in an old Jago Owners Club magazine:

 

[Lee]

Today was a good day. Lots got done and it’s a shame not all the parts were available to finish the build.

The fun part of all the Zed builds. Love this stage of putting all the shinny bits together and admiring the journey.

We’ve started lowering the car onto the subframe, inserting nuts n bolts and lifting the subframe back up with the car. Didn’t take long after this stage to get the shocks bolted back in and the arms under tension.

The Schnitzer springs looking the part. No brakes connected as they’ve not come back from paint yet. Did attempt to fit a new Guibo bush but found it was the right size but wrong diameter bolts, luckily the old ones not that old and can still see the brand Jurid stamped on it.

after the prop it’s heat shields then exhaust.

down pipe repair worked a treat. All fresh bolts for snugly.

underside now all looking very tidy. Been Waxoyl under sealed front to back.

Lovely job

once I get the brakes back it’s MOT and Tracking. Just a few little jobs left, brake line clips, quick oil service, also need to remake the front brake lines.

 

[Lee]

Today was a good day. Finally I got the brakes and the remaining bits to finish her off.

First job was getting the rear brakes all together. The yellow works so well.

all looking brilliant at the back.

Upfront was way more hard work. The lines were seized solid so needed replacing.

then arch liners back in and a good wipe down.

just got to pickup a rear brake pad sensor and she’s ready for the MOT Wednesday followed by tracking. Shame she’s going back in storage after this.

 

[Lee]

Test drive went well. Can really feel the 2.8 roll bars, she barely leant in the corners. Once warm quickly back on the ramp for a quick service.

filter didn’t look old. Car only has 40k miles so I’m not surprised.

quick lap of the block and she’s now ready for her MOT in the morning.

 

[Lee]

Forgot to add I hid a ZedShed sticker under the car

 

[MuttyMax]

Ha …. did i get a sticker on my “fast and dirty” or are these reserved for full resto only?

 

[AntStark]

That colour with those Style 32s looks amazing