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Discussion Starter #1 (Edited)
MasterC17's 2005 330Ci ZHP Project Build

Background:

Basically, I was looking to purchase an 01-03 330Ci. Needed to be a manual, with ~55k miles, good colors, and mostly a good price (max about $12,500). I started my search around two months ago and I looked at a few cars during that time frame but none worked out (one was an automatic, etc. etc.).

And one day I found a salvage, wrecked 2005 330Ci ZHP. It was perfect, colors were great, 6-Speed Manual, Cold Weather, 54k Miles, etc. :thumbsup: Now, obviously this was going to be a risk and I didn't want to end up with a bunch of money in the car. In the end I bid what I believed it was worth to me and I got it! Within a week I had sent the money to the dealer and was ready to go pick up the car.

The Pickup:

The car was located near Philidelphia, PA, and I am close to Boston, MA. Yesterday (day after Thanksgiving), my father and I loaded up and set off to get the car. It took us almost exactly five hours to get down there and we arrived at 10 in the morning. We checked the car over quickly, it was just as we expected with no surprises.

Next, we picked up the U-Haul trailer (had to buy a ball and different wiring...:banghead:) And we headed back to the dealer. Once there we loaded up (that was a hell of a time :eek:). And lastly, I signed the Bill of Sale, got the the Title, etc. and off we went. It took about six hours to get home, and we got back around 5:30. At that point we were both done for the day.

The Project:

Basically, I want to complete my car within two months at a reasonable price. All parts will be Factory, OEM (not from the stealership though :p) Most all of the work will be done by myself (except the inner fender work and paint). Overall I want to make the car look just as it did BEFORE the accident while spending a reasonable amount all with factory parts. The work will be high-quality and it should be as if it had never been hit at all.

Phase I: Breakdown:

Today, we went in and unloaded in the morning. Here is how the car was right after we pulled it off the trailer and into one our bay's: (sorry, first set of pics are crappy):facepalm:









The damage on the car is pictured, and is contained to the front of the car :).

Step I: Remove Hood:
Very simple, one hood shock is blown, the other is intact. All wiring, insert, and even the emblem (amazingly) are good. Hood, not so much.




Step II: Remove Headlight & Misc:

Left Xenon is near-perfect, top two clips broken but can be repaired. Removed other little things before the bumper.



Step III: Remove Front Bumper:

The bumper is suprisingly intact, the reinforcement is just barely bent, so really the only bad part is the bumper cover. Grille insert is good as well.




Step IV: Remove Radiator Support:

The radiator support came off pretty easily, but as you can see it is mangled.



And this is how the car stands now:




The really GOOD part is that the frame rail is perfect, no bending or likewise at all!



Here's some close ups of the body damage:




And that is what was accomplished today, I will update as progress is made. :hi: Next step is to purchase a Radiator!
 

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Looks like a cool project. I can't believe that car was considered to be totaled.
 

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You can buy the fender apron from the strut tower forward. And you can buy the fender support(the part the fender bolts to) from the cowl forward. A straight forward repair. Even though the frame rails look good, have a body shop measure it ti be sure. Money spent here is money VERY well spent when you go to put the car back together. I think that this is the ideal builder car, good pick. Even if you send it out to get the inner apron replaced/repaired,measured, and painted, you will come out smelling like a rose. Don't be afraid to get used parts for it. On a newer car like this, there should be plenty of good used parts for it. Just don't get after market sheet metal!! But it sounds like you know that already. Good job!!
 

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Confratulations, nice find. :thumbsup: No airbags deployed, I trust.
If this car was mine, I would not have let it go after the accident. Well, probably I wouldn't leave even my 323i if it gets this kind of damage.

Pitty I don't have time at all to go to salvage autions.
 

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Good luck with the rebuild. Keep us posted on your progress. I can't believe they totaled that car. Did the air bags deploy? :thumbsup:
 

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nice ride, gl
 

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You can buy the fender apron from the strut tower forward. And you can buy the fender support(the part the fender bolts to) from the cowl forward. A straight forward repair. Even though the frame rails look good, have a body shop measure it ti be sure. Money spent here is money VERY well spent when you go to put the car back together. I think that this is the ideal builder car, good pick. Even if you send it out to get the inner apron replaced/repaired,measured, and painted, you will come out smelling like a rose. Don't be afraid to get used parts for it. On a newer car like this, there should be plenty of good used parts for it. Just don't get after market sheet metal!! But it sounds like you know that already. Good job!!
This sounds like very good advise. When I looked at the pics, I too was thinking about the frame rail and strut tower being moved a few degrees, where you couldn't see it by eye, but would frak handling. Getting good measurements and adjustments as required now makes a lot of sense.

Looks like a great project, certainly looks all repairable. Good luck!
 

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so might I ask what you ended up paying for her...?...looks like a great find...not that much damage really...cannot wait to see it put back together....perfect time for a good looking cabfib hood...keep pics coming !!!
 

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Discussion Starter #14
You can buy the fender apron from the strut tower forward. And you can buy the fender support(the part the fender bolts to) from the cowl forward. A straight forward repair. Even though the frame rails look good, have a body shop measure it ti be sure. Money spent here is money VERY well spent when you go to put the car back together. I think that this is the ideal builder car, good pick. Even if you send it out to get the inner apron replaced/repaired,measured, and painted, you will come out smelling like a rose. Don't be afraid to get used parts for it. On a newer car like this, there should be plenty of good used parts for it. Just don't get after market sheet metal!! But it sounds like you know that already. Good job!!
Thanks for the advice, I was planning on getting the support and the cowl. Also, I'm going to have a body shop line everything up correctly. I'll be calling a few junk yards to try to find parts.

Good luck with the rebuild. Keep us posted on your progress. I can't believe they totaled that car. Did the air bags deploy? :thumbsup:
Actually, the driver's airbag did deploy, but the pasenger and side airbags did not, so it was a pretty light hit.
 

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Discussion Starter #15 (Edited)
MasterC17's 2005 330Ci ZHP Project Build 11/29/09

Phase I: Breakdown: (Continued)

Step V: Remove Belly Pan:

Removing the belly pan was a breeze, but there was a lot of broken stuff on it.



Got out all the intact parts and vaccumed up the rest.



Step VI: Remove Radiator:

Removing the radiator was a pain in the arse, and we had to clip the connector to the coiling coil. :facepalm: The radiator still had coolant in it and it and the steering pump still had oil and both went EVERYWHERE. We cleaned it up and it's done leaking now :).




Step VII: Remove Intake:

Hadn't planned on this but found out that the intake is shot. Got a big crack in it. Only good thing is I can order a Dinan one now :woot:



Step VIII: Remove Airbag:

Well, I tried to remove the airbag. I got it out, except the wires won't disconnect. On further inspection, the clips on the wires actually MELTED into the plastic (I assume from the airbag explosion on deployment). For now, the airbag will sit there.



Phase II: Inspection:

I already found out most of the problems, etc. but there were still little things to be found.

Step I: Right Door:

The right door is perfect, except for a little scrape right next to where the fender would have been.



Fortuanetly, this didn't effect the structure at all and the door lines up and open/closes perfectly.



Step II: Right Fender:

Obviously, it is gonzo. Good part is the wire for the turn signal is good and so is the turn signal itself!



Step III: Front:

Once everything else was removed, I inspected the front and there is nothing wrong :). Every bit of damage here was contained in front of the engine.



Step IV: Left Fender:

The left fender is good although it was tweaked a teeny bit. Looks suspicously like someone meant to do it...



Step V: Left Door:

The left door is perfect, and the door lines up and opens/closes good :)



Step VI: Few Other Things:

1. The windshield is cracked although I already knew that.

(Picture makes it look worse than it is)


2. The ground wiring was cut in one spot by the fender on impact, but we bent the fender back and are going to splice the ground that was cut back together soon.



3. This thingy broke (haven't taken time to fiqure out what it is yet). And the A/C Drier line is tweaked but looks like it can be shaped back to normal.



The Good:

Ballast's for Right Xenon, Right Turn Signal, Carpets in the trunk. :craig:

Overall:

A little more than I had anticipated, but that is to be expected in a wreck. Overall it was a very light hit that was on the borderline of a total loss or not.

Will continue to post as I make progress. Calling a few Junkyards tommorow to see if they got any E46's!

Interior Picture:

Just wanted to show a picture of the interior, sorry for the bad quality.

 

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Plug up those A.C. lines Mister! Don't want ANYTHING to get in there. You will want part number 3 and 4.I'ts very common for the plugs to the airbag to be melted.You will need the bag as well as a clock spring.The left fender being pushed out like that is an indication that the front end is pushed over,no big deal, this is why is suggested to get it measured.

If I can help answer questions for you,just ask or pm me! Happy to help.
 

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If you are able to locate any Junkyards around Boston with E46's in them please let me know! Cool project, where in MA are you located?
 
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