Replacing frame rail and straightening using laser: Crashed BMW E36 Tracktool repair

Описание: Let's start with a review of parts I got for this repair - used front chassis rails from another 316i coupe E36 (even these are all the same on all E36 models), all front body panels, used but good front subframe and most importantly - brand new X-Brace from BMW E36 M3 or Z3 models. That will help me to make more precise work and later on it will reinforce whole structure.
DISCLAIMER: This BMW E36 won't be for sale or rent. It will become a personal tracktool to bring more joy to everyday life!

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Dirtiest part - welding work and preparation for painting... Thin sheet metal with some primer and undercoating - perfect combo to become as dirty as you can both when welding and grinding everything... But parts started to fit chassis quite quickly and I could start doing more measurements.

Using construction laser and levelling car according to it I could verify not only distances between the points - but also height difference. It's a very fast and precise method to get car straight and any 2 same points on different sides of the car can be checked in seconds. Just after I installed subframe and X-Brace - which for my surprise fit perfectly! All mounting bolts went in just with hands - it means ALL points are perfectly aligned and in correct positions!

Quick test fit of fenders, bonnet (hood), front lights, bumper and grill holder - all roughly fits, so I could continue to weld everything together permanently! Firstly I used mostly just screws, so if needed to do some adjustments - I could do that quickly.

Just before putting primer, base coat and clear coat to paint engine bay - I have applied Seal Sealant. Manufactures use high pressure special guns to apply it to make a pattern, bet thats a tricky process requiring special tools and most importantly skill - otherwise sealant would go everywhere where it is not needed and wouldn't make much help. I used simple tools - but difficult sealant applying technique. It came out perfect!

Final part - painting. After seeing my dirty face - Linas came to help, huge thanks for it! We sprayed engine bay and newly attached chassis rails rather quickly - but result came more than perfect! Primer, then base coat and finally clear coat. It's way better than original look and will be washed much easier in the future!

In the next episode we will assemble this BMW, will put back M50 / M52 B25 engine and hopefully it starts without problems after standing still for more than 2 years already!