Mat Armstrong's BMW E24: Gull Wing Door Conversion & Restoration

E24 Restoration Progress

• 💡 This episode continues the ongoing restoration of Mat Armstrong's BMW E24, marking the 43rd installment of the build.
• 🚀 The previous episode featured a complete redesign of the car's sides, setting the stage for further extreme modifications.

Chassis & Roll Cage Preparation

• 🛠️ All old bushings were stripped from the running gear to prepare the components for powder coating and ensure perfect foundations.
• ✅ A half roll cage from SW Motorsport was installed, with its primary purpose shifting to support the upcoming gull-wing doors.
• 🧠 The car's interior was 3D scanned using a Revopoint Metro Y Pro to accurately design an extended roll cage that integrates with the gull-wing mechanism.

Gull-Wing Door Design & Fabrication

• 🔑 The gull-wing door concept involves a complex mechanism where the doors and a portion of the roof will pivot upwards, leaving only a small central roof strip.
• ⚖️ A major challenge is lightening the doors, as the original E24 doors are frameless, and the new design adds significant weight.
• ✂️ The door cutting strategy was refined, opting to raise the bottom cut by 160mm to remove substantial weight and create a functional step for entry.

Cutting & Reinforcement

• 📏 Precise cutting of the door was performed, carefully aligning with the wing mirror and maintaining the E24's aesthetic lines.
• 💪 The cut door was test-fitted to the car and will be reinforced with new panels to ensure structural integrity and provide an edge for rubber seals.
• ⏳ The next steps involve cleaning, priming, and welding the newly fabricated door sections for final assembly, ensuring a durable and tasteful finish.