New member - Rebuilding an 08 535xi
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New Members
Joined: Apr 2014
Posts: 58
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From: Edmonton, AB
My Ride: E60 535xi, E90M3, E92M3
That would be the headlight baffle, number 2 in this diagram:
RealOEM.com * BMW E60 530i WHEELHOUSE/ENGINE SUPPORT
It's cold bonded and riveted aluminum. I don't know how bad off yours is, but I have seen what the repair attempts look like, and they're not good. It only takes a couple of whacks with a body hammer to cause it to completely split in two. Again, these panels are all bonded aluminum and should only be replaced in a damage situation.
Not trying to give you a hard time, but it's very easy to get in over your head when you're talking about structural repairs on an E60. Last year I saw a car where someone tried to repair the very panel you're describing. They ended up sending the car to BMW for a full right apron replacement to the tune of $8000, because the failed repair attempt not only trashed the baffle panel but the mating seam where the baffle meets the apron.
RealOEM.com * BMW E60 530i WHEELHOUSE/ENGINE SUPPORT
It's cold bonded and riveted aluminum. I don't know how bad off yours is, but I have seen what the repair attempts look like, and they're not good. It only takes a couple of whacks with a body hammer to cause it to completely split in two. Again, these panels are all bonded aluminum and should only be replaced in a damage situation.
Not trying to give you a hard time, but it's very easy to get in over your head when you're talking about structural repairs on an E60. Last year I saw a car where someone tried to repair the very panel you're describing. They ended up sending the car to BMW for a full right apron replacement to the tune of $8000, because the failed repair attempt not only trashed the baffle panel but the mating seam where the baffle meets the apron.
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Joined: May 2012
Posts: 2,539
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From: Tampa Bay, FL
My Ride: 530i
Model Year: 2004
Engine: M54
Hi Kyle, I totally appreciate your input as its quite obvious you're knowledgeable in the industry. I know exactly what you're referring to with how easy it is to split..etc. We were able to straighten it out as it really wasn't bad at all. I'll show you the before/after pics as soon as I have a minute to upload them (hopefully tonight) In the pictures, you'll be able to see the bend and the repair after.
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New Members
Joined: Apr 2014
Posts: 58
Likes: 0
From: Edmonton, AB
My Ride: E60 535xi, E90M3, E92M3
Bit of an update here..
April 26th, my guy came over and helped me with making sure everything was straight and lines up
And this
It probably happened when the headlight was hit and pushed in the area. So we took it from this, slowly shaped it back..
here you can slowly see the progression.
hammering away..
At this point we were pretty darn close, so we test fitted the fender to see how everything lined up
Here it is, pretty close to it's final form...
In this picture, you can see the dented strut as well. This is on order, and should arrive on tuesday
Finished the massaging and lined up the fender.
This is the slide hammer that we used to pull the bent corner and straighten it.
Getting it closer to its final form.
Just a bit more..
Now we test fit the headlight/fender/hood.
in these 2 pictures, the fender is bolted on, except I haven't tightened down the final bolt on the very top up by the pillar.
Ran out of time for today, Now I'm waiting on some parts but I probably won't be able to do much until I get back from Anaheim in May.
April 26th, my guy came over and helped me with making sure everything was straight and lines up
And this
It probably happened when the headlight was hit and pushed in the area. So we took it from this, slowly shaped it back..
here you can slowly see the progression.
hammering away..
At this point we were pretty darn close, so we test fitted the fender to see how everything lined up
Here it is, pretty close to it's final form...
In this picture, you can see the dented strut as well. This is on order, and should arrive on tuesday
Finished the massaging and lined up the fender.
This is the slide hammer that we used to pull the bent corner and straighten it.
Getting it closer to its final form.
Just a bit more..
Now we test fit the headlight/fender/hood.
in these 2 pictures, the fender is bolted on, except I haven't tightened down the final bolt on the very top up by the pillar.
Ran out of time for today, Now I'm waiting on some parts but I probably won't be able to do much until I get back from Anaheim in May.
Thread Starter
New Members
Joined: Apr 2014
Posts: 58
Likes: 0
From: Edmonton, AB
My Ride: E60 535xi, E90M3, E92M3
The tire on the wheel popped, and with moving it around the storage yard, the tire eventually came off the beed and was rubbing up against it. The strut is a very thin metal.
New Members
Joined: May 2012
Posts: 35
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From: Canada
My Ride: 2008 528i, Black Sapphire, M5 front, 2piece Niche Touring II, Nitto Invo, H&R
As someone that's seen a ton of rebuilt BMW's, Mercedes', Lexus, this small damage is seriously nothing in the grand scheme of things. You're going to get a fantastic car when this is done for 1/4 of the price of a non-salvage title.
People will typically hear the word 'frame damage' and run for the hills, but here in B.C, ICBC will write anything off when there's frame damage, and professionals can fix frames back to near-factory specs anyways.
Good on you and best of luck with the repair. Definitely go M5 front bumper from the start, you'll be glad you did.
People will typically hear the word 'frame damage' and run for the hills, but here in B.C, ICBC will write anything off when there's frame damage, and professionals can fix frames back to near-factory specs anyways.
Good on you and best of luck with the repair. Definitely go M5 front bumper from the start, you'll be glad you did.
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