Project Chronicle

A few days ago, Jay of Jay's 4WD called me with a query. He said after removing the head, he was surprised to see just how far the chain reached down into the oil pan. Jay recommended replacing the chain as a sensible "while you're in there" project, but after seeing how it snaked through the very lowest point of the engine, he suggested we remove the whole assembly. This would free up space in his shop while waiting for the head to come back from the machine shop, and also make it possible to replace the oil pan gasket and rear main seal as further "while you're in there" projects.

Unfortunately, in an unrelated call today, Jay mentioned we're going to be spending more time at the machine shop. Upon closer inspection of the block, Jay noticed signs of rust on the surface where it mates with the head. He said he could just throw it all back together, but that he wouldn't feel comfortable offering anything close to a guarantee that I wouldn't have future headgasket issues. Further, he said most shops wouldn't even do the work knowing there was rust around the cylinder bores. 

This creates two problems: one, of course, is that this truck continues to be more of a project than I ever anticipated. The second problem - and more of a concern - is the timeline. I was hoping to have it back at the end of March but the machine shop is already working out several weeks, if not months. At the end of the day, there's really not much of a choice here, especially since Jay has a relationship with this shop. We'll do piston rings and guides at the same time, and while all of this is spiraling way out of control, it continues to further guarantee the LX450 will be damn near bulletproof when it's done. 

Are we having fun yet? 

Trying to keep the status on my 88iS mostly OEM+....I really like the factory 14" basketweave that came on the U.S. iS E30s, but sadly another thing the US market didn't get from BMW, the 15" 'Euroweave'. The European spec sport wheel/basketweave was superior to ours, and though its subtle only being 1" bigger...It also has a deeper lip, and its extra size allows a lot more tire options. 

Knowing this, I started the hunt and eventually found a very friendly fellow E30 Enthusiast from the UK. From him I purchased a freshly refinished/painted set of 15" Euroweaves. These really help fill in the wheel arches and give it a more aggressive look. 

For tires, I decided to go with the Continental Extreme Contact Sports in all four corners. Up from 195/55/R14 to 205/50/R15, the new tires really dialed the car in and reduced a lot of roll. The grip from the summer tire vs. All season compound truly makes it a completely different experience!

Now this last part may make me sound crazy, but I swear I have noticed the steering has gotten a little heavier due to the extra weight of bigger wheels...Trade off is worth it though!

P.S. 

Anyone have a lead on Euro caps? They are harder to find than the wheels! 

For me and most of us enthusiasts, hearing the car is an extremely obvious and exciting way to enhance the driving experience. But, like I said in my previous post, I want the car to remain relatively OEM+ without doing anything too crazy and obnoxious. After a lot of research and hours on YouTube finding sound clips, I decided to go with the Strömung E30 325i specific catback exhaust. I read some good things on the R3V forums, but quickly realized the posts were years old. I reached out to the company and the owner, Scott, was extremely receptive and personally interacted with me. Though they didn't currently produce them at the time I bought mine, he got the BPs and made one for me anyways. The quality is second to none, finished in a super nicely crafted polished stainless steel construction, resonated exhaust tips, and some of the better welds I have seen on an exhaust system.

Quite honestly, its not as loud as I wish it was, and sometimes I feel dumb spending the $ to make it just a little louder...But, it looks much better, and is probably the equivalent of a modern day factory optioned 'M Sport Exhaust'. Again, OEM+ was my goal!

One of the few bright spots of the surprisingly endless Lexus LX450 project is the mechanic I have working on this truck. Jay, of Jay's 4WD, first came into the picture when I searched for someone to revive the long-dormant Isuzu Trooper RS project. Jay is a talented wrench, and he's since taken on the revival of my '98 Dakota R/T project.

I've used the local Lexus dealer for repairs on the LX for two reasons: one, a mechanic I knew from a previous project had since taken a job there, and two, it's entirely convenient because the dealer is close to my house. But when the headgasket issues materialized, I decided to move it down to Jay because I was growing weary of the dealer mentality that they would fix anything I'd like but didn't necessarily have the intuition to deduct months ago that headgasket issues were looming.

Jay has already dived in, and within two hours on a Saturday morning, he had the head removed from the LX450's inline-six and was in my neighborhood shortly after that to drop off the head. I'm going to run it over to a local machine shop that Jay has used for his boat engine repair business, and hopefully, we'll find the head is free of any cracks and can be decked and cleaned, ready to drop back in. 

While I have been bummed out by the amount of work the seemingly most-reliable vehicle in my fleet has needed, I'm excited at the prospect of having a truck with almost every major mechanical component replaced - some much-needed peace of mind for a truck I intend to make my daily driver in the spring. 

When I first got the Mercedes-Benz 190E 2.3-16 Cosworth home, I reached out to the dealership in Pennsylvania that was listed on the service reminder sticker in the windshield. I asked if there were any records of repair available, to which the service manager confirmed that yes, they did.

Amazingly, the service manager said he'd send me copies of the records they had on file, which were surprisingly complete. Now, most dealers will never release the service records, so I'm forever grateful this advisor agreed to do it. I look at the report every now and again, which confirms the 190E was well maintained before it ended up in the hands of the last owner before it went to the salvage yard. 

The most interesting detail is that it dropped a piston at just over 66,000 miles. In terms of the Cosworth engine, there's not much evidence that the DOHC mill has a tendency to burn through pistons. Although the details are sparse on the service reports, I've always been curious how extensive the repair was, and if the dealership made other fixes "while they were in there." 

We'll never know for sure what else was fixed at this time, but it's a fascinating anecdote in this car's colorful history. 

I finally had the chance to flip through the service booklet that came with the 911. Now, the bulk of the records came in the form of invoices from specialist shops in North Carolina and Georgia, and those were certainly compelling reasons in my decision to buy the car.

That said, the tried-and-true method of tracking a car's history - the maintenance booklet - can be just as valuable. In the case of this car, the stampings were limited but meaningful. The early part of the car's history showed a few dealer stops in Wisconsin after being sold new by a fairly prominent dealer in a wealthy Chicago suburb. After it arrives in North Carolina, however, it makes two stops at Road Scholars. 

Road Scholars is one of the foremost Porsche restoration shops in the country, if not the world. Between their personal collection of significant air-cooled Porches that routinely win at major Concours like Amelia Island and Pebble Beach and being hired to take on the restoration of historical and culturally significant cars, Road Scholars has an iron-clad reputation in the Porsche community. 

This car already had a strong portfolio of proactive maintenance, but seeing Road Scholars in the maintenance book suggests a prior owner was only keeping the 911 serviced by the best of the best. I hope to get in touch with Road Scholars soon to see if they're willing to share whatever invoices they have on file for this car. 

For years, I have proclaimed my undying love for the 1986 Mercedes-Benz 190E 2.3-16 Cosworth I rescued out of a junkyard in Pennsylvania. Let me explain why. 

It's the car I wanted since I was 16; it somehow corrects the emotional debt I carried for years following a junior prom date not becoming the girl I would marry (despite hoping with every fiber of my being that it would be so.) I looked at a Cosworth at a local car lot with my Dad shortly thereafter and he was ready to buy it as a consolation prize (my father did not spoil us, but he followed a code that prompted him to act impulsively and out of love when his kids were truly hurting.) Suffice it to say, his colleague that owned the lot specializing in desirable European stock told him I'd put it into a tree within about a week, and that was that. 

I know, there's a lot to unpack there, but this is why I buy needy cars - it absolves me from seeing a therapist. Anyhow, a Cosworth has remained on my car-buying radar for years. I've had opportunities to buy driver-quality examples but never felt inclined to do so. For some reason, buying this rusty, half-pillaged junkyard find was the trigger for finally bringing one home, which I find aligns curiously with the state my sixteen-year-old self was in when Liz and I didn't pan out way back in the year 2000 (God, that is a long time ago now - why am I still talking about this?) 

So, to see the Cosworth entering its most prolonged, expensive, and agonizingly tedious phase - that is to say, bodywork and correcting years of neglected rust concerns and shitty repairs (I swear, they repainted this car with three times the necessary material - the finish is so ungodly thick) is giving me heartburn. Look, it's expensive, and I'm using the most sketch-ass version of a body shop there is, the equivalent of a backdoor card game in a bad neighborhood with prostitutes doubling as bouncers. It's the only way someone like me can afford to take on a dumb-fuck project like this. 

I hate it. I love it. I hate seeing updates from the guy working long hours in a dingy garage with no ventilation because I know I owe him another $300 for something I didn't know was broken; I love it because I see that shape come back to life and all the emotions come roiling back, like I'm going to drive past Liz's house in this car and flick her off, just like I planned to do when my Dad was ready to pay Chuck Mitchell the measly $9,000 that would've bought a nice one of these 20 years ago. 

All of that is in the past. It's just in the past. But the Cosworth is here now, and while I continue to chase every side hustle I can find and chuck shit onto craigslist in hopes of a quick buck or two - all driven by getting this project done this year - I find myself in that uncomfortable middle ground of wondering why we do this to ourselves as car enthusiasts, while simultaneously already knowing the answer. 

I regret to inform you I did not escape the dreaded headgasket failure on my '97 LX450. 

Truthfully, I saw it coming. I had ignored some of the tell-tale signs and written them off as irrelevant. The entry in the history file indicated around 230,000 miles, an overheating event occurred, with subsequent entries showing a new thermostat, water pump, and radiator did not resolve the issue. Then it goes quiet, and another 20,000 miles are logged before I buy it. 

I noticed a good amount of dense steam at startup - warm weather or cold - that looked like condensation but also had that awful smell that only burnt coolant smells like. But it would go away once the truck was warm, and I wouldn't see it again until the next cold start. 

Then, an overheating event on the way back from vacation seemed to be tied to a dead fan clutch. Two more months of even-temperature gauge bliss. But in December, on a frigid night, I ran out of heat and the truck began to run warm. It was parked at the local Lexus dealer for a month wherein my friend Joe, the lead tech, observed the radiator was empty. He thought it was not the headgasket as a pressure test revealed no sign of exhaust gases in the system. But with no other explanation as to where the coolant was going, and the radiator otherwise intact, he pulled the spark plugs and saw the dreaded sign of internal coolant leaks. 

To be perfectly honest, this was not an expense I anticipated. And I had just decided my plan going forward was to sell my E91 in the spring to shore up the maintenance budget; buy a 996; and use the LX450 and Dakota R/T for occasional daily driving duties. 

The new plan is to get the Lexus down to my friend Jay, who revived the Trooper, and works almost exclusively on old Toyotas. This pushes everything off a bit but I need to get the Lexus buttoned up once and for all. And truthfully, once the HG and chain are done, there's very little else that can go wrong on this thing. God willing. 

Just a quick update here: the Mercedes-Benz 190E 2.3-16 is coming along. We're chopping up the bodywork into phases so I don't go broke. First is the rear of the car, which is the worst and most complex. 

Fortunately, $160 worth of replacement rear quarter panels and a $180 taillight panel are saving my butt and budget. These pieces have been chopped up to repair various sections of the rear quarters (with the exception of the taillight panel, which was just cut out entirely) and have yielded significant time and material savings. I have no idea why a Japanese company sells replacement quarter panels for a W201 chassis car, but I am glad they do. 

The trunk lid has to be repaired next. I bought a junkyard lid which we will use to swap the Cosworth spoiler over to, as the original trunk was too heavily damaged by the bozos at the salvage yard that ripped it open when they couldn't find a key. 

Once this is done, it will be sprayed with primer and parked until I can scare up the cash for the rockers.