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Project "Sooty"

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  • Project "Sooty"

    Was a little worried that this project would be a bit out of place on here, but after asking Steve's (fatty) advice, I'll pop it on S2forum too. You can see how a dog of a car gets a little modified and some MUCH needed TLC after years of non-attention.
    Nothing compared to some of the projects in here, but this is a little different in that it's being done on a strict tight ass budget.
    It does have a turbo after all.

    As a lot of us on here are discovering, the 80 TDi makes a sound economical buy these days. Was just after Christmas I thought again of a work hack again after my Audi 90 2.3e auto decided to munch it's autobox last year.

    First off, excuse the name of the project, my other half thinks all diesels are "sooty" and has called this car that. It's sort of stuck, but I prefer the "chip pan stinker".

    As we all know, this robbing no good government of ours is pushing the price of petrol up and up and up. The 2p rise planned for April is on top of the extra £3 billion our great chancellor Mr Darling (how gay is that name?) has raked in over the past 6 months due to the rise in the price of a barrel of oil, but will he scrap that 2p rise? Like **** he will.
    When I bought my S2 Coupe 4 years ago, I could fill it's 70 litre tank for roughly £55, that same fill now costs me a nats nob off £84.
    As I use the S2 to travel the 50 miles return trip to work 5-6 days a week, and with the S2 returning an average mpg of 25.5, it's getting a tad expensive.
    What to do? Sell the S2? No way! why the hell should I?
    It's a fabulous car to drive and I have no plans to get rid of her for a long time yet, though I have had my moments, usually in anger to do with daft silly failures.

    Thought about a few various other cars, another cq20v, another 2.3e manual Coupe, a 90 20v quattro, another 80 V6 quattro.
    But all aren't going to save me the money in fuel costs.
    That means a diesel. Again I had some preferences to fill, main one being it had to be a B4. Had to be a TD"i" so it would "effortlessly" do the work run down the motorway every day.
    Didn't fancy an Avant as I'm still only 37 and nowhere near needing or wanting to own a pipe and some tartan slippers to go with it. :mischeif:
    That leaves the 80 1.9 TDi saloon.
    Again, it needed to be (to me) not in perfect condition. As long as the mechanicals were fine, the bodywork could be scruffy. As long as it wasn't full of holes and every panel didn't have a football size dent, I'd do.
    Step forward a user of audifans.net who was contemplating scrapping his old 80.

    It sounded just what I wanted, as long as the rear ender it had had, hadn't been too bad.
    In reality, apart from a some cracks to the paint in the middle of the rear bumper, that rear ender affected nothing else.
    Front drivers wing has had a pattern part replacement in the past and is rotten now, full of holes on the arch. Thinking of pattern part replacement panels? DON'T! they are crap. The car should be laser red, but is the fabled laser pink. Not worried about that as I'll get it back to it's former glory.

    I also wanted to experiment with alternative fuels. Pump diesel is refined petroleum and not what the inventor of this engine (Mr diesel) originally designed them to run on. Ok todays diesels are designed to run on pump diesel, but good old biofuel or SVO is the future.
    I plan on running it on a vegetable oil and pump diesel mix.
    I've already got vegetable oil in the tank now. I've let the tank run near empty and filled it with 30 litres of pump diesel and 30 litres of vegetable oil. I bought 50 litres of vegetable oil (sunflower) off a friend who works for a trade cash and carry for £22, that works out at about 45p a litre.
    The car is running fine on this, no problems so far although to be honest I didn't expect any.

    Ok, to the car itself. It was picked up on the 9th of feb from Coventry for a paltry £250. Caught the train to Tamworth, audifans.net owner and AOC cheif Andy picked me up and I headed home the next day.
    The car came without a radio, so before leaving Tamworth a trip to Halfords and back saw me buy an new RDS tuner headunit with CD-R front loader for £40. Fitted in a crack by Andy, it's not as bad as I thought it would be for £40, radio reception is fine, plays CD's no bother and the sound quality is ok, but MILES away from the Becker headunit recently fitted to my S2, but then that was £300 so you'd expect some difference.
    Drive home was great, the car is quiet, VERY economical, brakes are good, engine pulls very well, clutch good, gearbox good. The previous owner had had a bit of a problem with it late last year, he'd posted asking for a good midlands VW/Audi specialist and I'd directed him to Jason at the Lion garage. Jason replaced the diesel pump and also did the cambelt at the same time. So I'm not worried about the engine.

    Monday saw me with a day off work, so first off was to change a few interior items. The ugly four spoke steering wheel had to go, in it's place a spare 3 spoke sport wheel was put on instead. Most of the small 5mm wedge bulbs throughout the car on things like the switches, the heater controls etc were out. I've replaced all of these, every last one in the car has been replaced even if it was working or not. This means they are all the same brightness and should in theory save me having to pull stuff apart again when another one blew.
    Dash binnacle bulbs were out on all but two of them. So they've all been replaced too.
    The interior was rank, so the seats and carpets were vacuumed (took "three" hours) and then cleaned with a vax and carpet shampoo. All the trim and dash was washed down with neat Megs APC and then treated to Aerospace 303 trim protectant.
    A set of mats were added (ok, coupe ones, but I had them so used them)


    A spare genuine used wing was given to me by Andy, it came from his recently sold 80 avant and is in emerald green. I'm also a big hater (personal preference don't forget ) of the standard front bumper, what possessed Audi to design it looking like a speed boats hull I'll never know, so that's coming off. In it's place a spare S2 front bumper from my collection (I have three of them, no sorry, not for sale either).
    With that I'll have to change the headlights or I'll have four front indicators. So a set of face lifted coupe headlights will go in, with some clear indicators and the fogs in the new bumper.
    I'll be colour coding the door handles and the wing mirrors, along with the black rubbing strips mid way up the doors. That leaves the rear bumper being removed and replaced with a S2 avant rear bumper recently sourced (Cheers Matt )
    All above will be done by myself, apart from the laser red top coat on the wing and bumper as I can't get the finish I want. £40 is what a mate wants to do this, so I'd rather he did it, than me doing it and always hating it.

    Lastly, the wheels. Currently it's on it's original steelies, 195/65/15 with no wheel trims either. I want alloys though. I have a set of 17" five spoke alloys that would look great, but the tyres are really best their sell by date and I'm not keen on 17" after been there with them on my S2. Though after driving this car for a while now, I think the 17's won't be that bad. The S2's suspension is SOOOO much harder than this shuggy boat 80's suspension.
    So, as this is a cash saving car, I'm not about to fork out for some tyres. I have a spare set (two spare sets really) of 16" avus wheels with brand new tyres on them. But as we know, 5x112 avus don't bolt to 4x108 hubs. Five stud conversion? Nope, that'll cost money, is not exactly straight forward and so far, not what I want to do.
    Hub converters? Hmmm? There is one place that sells them in Belgium, but at 300 euros a set + shipping they are a little expensive. Plenty of 4x100 to 5x100 or 4x100 to 5x130, even a 4x108 to 5x130.
    If I can't get them easy, then maybe I'll make some.
    Also looking into the possibility of turning my 4x108 hubs themselves into 5x112.
    I know I know, some will cry and protest that your wheel will drop off, you'll end up upside down on the motorway with a central reservation barrier embedded in your head, but as the VW boys run with 4x100 to 5x112 or 5x130 converters without really bad things happening, I'll give one of these a shot. But not before carefully planning and weighing the idea up.

    Ok, pictures so far.

    This is the exterior as it was when I picked it up. Pretty faded with a few knocks and scrapes. Apart from the front driver wing (awful isn't it) they'll all repair with a little elbow grease and time. No rust anywhere else apart from that drivers wing.
    2001 Avus Silver B5 RS4.
    2004 A4 Avant 1.8T quattro Sport-LE.
    1995 S2 Coupe - sold (sniff)

  • #2






    First up was to sort the inside.
    Bit of hoovering, shampooing and dash trim dressing, it went from this;





    2001 Avus Silver B5 RS4.
    2004 A4 Avant 1.8T quattro Sport-LE.
    1995 S2 Coupe - sold (sniff)

    Comment


    • #3








      To this;



      2001 Avus Silver B5 RS4.
      2004 A4 Avant 1.8T quattro Sport-LE.
      1995 S2 Coupe - sold (sniff)

      Comment


      • #4










        I'm missing the dash badge but they are still available to buy new, not a lot at £7 or so. I'll also keep an eye on ebay for a full length switch panel and some balnks as I'll need to put in a front foglight switch and they isn't space as it is now.

        What I intimately want it to look like, and there's no reason to say it can't be done, is to visually look like an S2 saloon (never came to the UK, only 307 ever built) The avus wheels will obviuosly do that, but if that can't be done I guess it'll look like an 80 competition externally.



        I'll probably have to lower it, or it'll look like it's on stilts, but I can do that later on this year, possibly tying it up with top mount replacements as I think one is on the way out (got a spring twang going on).

        Wing and bumper are done and primed, off to painters on Monday. Should have them fitted "maybe" later this week, definitely the weekend.
        I will of course keep the thread up to date as I go.

        (Note, I'm editing, copy and pasting from my thread on audifans, so the timeline is a little off, just saves writing everything out again)
        2001 Avus Silver B5 RS4.
        2004 A4 Avant 1.8T quattro Sport-LE.
        1995 S2 Coupe - sold (sniff)

        Comment


        • #5
          Found the foglight connectors already in the loom for the upcoming fog in the S2 bumper One can be seen right down the bottom in the pic below. Just need to see if the plug for the switch is hiding behind the dash, but don't see why not.



          Still not the right weather for anthing paint spray related, spitting on and windy so no go on colour coding the trims (booo).

          Tidied a few things up, jubilee clips on the windscreen washer pipes junked and replaced with cable ties (they have a habit of popping out when they get old)
          Chopped out the expanding foam that had been used to try and repair a leaky bonnet release cable grommet (UTTER madness), it was covering half of the fusebox so I couldn't get in there to replace the dicky intermittent wiper relay (sometimes worked, sometimes didn't, leaving wipers parked anywhere they wanted)
          Bonnet cable undone at the slam panel end, new bonnet release cable grommet slipped on and moved around the cable into position in the bulkhead. That's that sorted. Forgot to take a pic of the grommet in position.



          Wipers now sorted.

          Boot loom had been butchered by Sweeny Todd in the past, so repaired that today.
          16 rolls of red inslutaing tape removed, wires extended properly, joints soldered and heatshrinked, removed a terminal block and covered the repaired loom in two long sleeves of heatshrink, cable tying the loom out of the way of the rubber boot seal as before it had been getting jammed in there, enough to damage it.













          2001 Avus Silver B5 RS4.
          2004 A4 Avant 1.8T quattro Sport-LE.
          1995 S2 Coupe - sold (sniff)

          Comment


          • #6
            As an update to the biodiesel part of the sooty saga. I've received a reply to my enquiries at HMC&E.
            I do not have to register with HMC&E as a fuel producer if I use less than 2500 litres of either SVO or WVO in any one calender year.
            Previously you did need to register, but as so many small home users were registering, they made a decision that unless you produce (in reality, buy) more than 2500 litres of "biofuel" then you are free to use this as a road fuel tax free.
            I'll be keeping records and receipts.

            2500 litres of SVO is 550 imperial gallons.
            550 gallons x roughly 45mpg = 24750 miles.
            That would be 24750 miles using SVO on it's own, which I'm not doing. It's mixed at least 50/50.
            I'm hardly going to be doing 24700 miles a year either.

            Not bad.
            2001 Avus Silver B5 RS4.
            2004 A4 Avant 1.8T quattro Sport-LE.
            1995 S2 Coupe - sold (sniff)

            Comment


            • #7
              Bumper and wing back from the painters. Not bad for a favour and bung
              Painted in good old two pack, none of this water based nonsense.







              Fitting at the weekend, again and as always...damn weather permitting.
              2001 Avus Silver B5 RS4.
              2004 A4 Avant 1.8T quattro Sport-LE.
              1995 S2 Coupe - sold (sniff)

              Comment


              • #8
                Weekend just gone. This was Saturdays job (01/03/2008)

                Weather held out, sort of. Not raining bit still extremely windy. Bonnet blew shut a few times, one of them on my hand. Nice big chunk taken out of three fingers and blood all over the shop

                Still, thoroughly enjoyed doing it.
                So, wing, bumper, headlamps, fogs, side repeaters and indicators are fitted. Also adjusted the drivers door, now has a nice easy click on shutting, rather than a clank and bang.

                It would have been rude to do the whole thing without snapping some pictures, so took a boat load while doing the lot.

                First up, out with the old headlamps and indicators; Being supervised by my trusty dog Oscar. He soon got fed up and legged back into the warmth of the house, the big girl he is



                Next up was to remove the bumper; Bloody hell, now that is one mother of a radiator



                Off with the wheel so I could remove the arch liner;



                Shockingly bad rust on the wing. VERY poor quality pattern part wing;



                2001 Avus Silver B5 RS4.
                2004 A4 Avant 1.8T quattro Sport-LE.
                1995 S2 Coupe - sold (sniff)

                Comment


                • #9
                  And the wing off the car;



                  Next up, adjusting the door while the normally hard to get to bolt is nicely exposed.
                  The door had dropped, so that meant I needed to adjust the bottom hinge out. I temporarily refitted the wheel and dropped it back onto the floor, as the body is twisted with one corner in the air, no use doing this with the body twisted.

                  Loosen the 13mm bolt circled in white, don't remove it, just loosen it off enough so that the hinge can move later (the hole is slotted)
                  Open the door and remove the 13mm bolt on the bottom hinge. Behind that you'll see a 12mm allen headed adjuster. You need to tighten this in, (clockwise) it winds in and pushes the bottom hinge out, moving it away from the door jamb. I didn't have my good set of allen keys with me, left the ******s at work, so solution was the find a bolt with a 12mm hex head, tighten a couple of nuts on the end of the threads and use this to turn the adjuster. Worked a treat.
                  Don't go crazy with the adjuster, just a bit at a time while keeping a check on how the door closes. Once happy, put that 13mm bolt back in a tighten it up. Then tighten the 13mm bolt you loosened off.
                  As someone will no doubt ask, yes it's exactly the same procedure for the Coupe, the Avant, the B3 80, the 90, and the cabriolet.







                  I didn't have the U shaped brackets needed for to hold the bumper to the other brackets that are used. Did have those thankfully, so just made the others out of some 2mm ally that I had. That saw the wing on and the bumper fitted on the front fixings. Fixed the bumper to the arches.







                  Next up putting the fogs, indicators, trims and headlamps in.
                  One side done;

                  2001 Avus Silver B5 RS4.
                  2004 A4 Avant 1.8T quattro Sport-LE.
                  1995 S2 Coupe - sold (sniff)

                  Comment


                  • #10
                    Then the other;





                    Done;



                    Still stuff to do tomorrow. Start to machine polish the car, currently looks three different shades of red. I "may" have to get the drivers door sprayed as it was previously sprayed along with that pattern wing and is ever so slightly a different colour. Got some new number plates on order, will stick them on rather than being fixed on with ugly screws.

                    One last thing. The removable black trim on the 80 front bumper. It can be removed and fitted with another trim that allows front fogs. I thought I'd pull said black trim off, see what is was all about. Just being nosey, as you do.
                    Look what was behind it
                    I pulled the drivers side trim off, but this was a passenger side fog. Not fixed in, just loose.
                    Question! Where in the name of god did that come from? why's it there? how long has it been there?
                    Thought I'd see if the other side had one...Nope, empty. :?
                    At least we now know that the fogs used when you fit them to an 80 bumper, are the fogs we all know.
                    Bit of a curve ball that one. Stood and scratched my head over that for a good few minutes.



                    Oh, I've deliberately not shown a shot of the new wing. I'll do that tomorrow after the car has had a good while under various lake country pads and some Menzerna IP and FF.

                    Off for a blood transfusion
                    2001 Avus Silver B5 RS4.
                    2004 A4 Avant 1.8T quattro Sport-LE.
                    1995 S2 Coupe - sold (sniff)

                    Comment


                    • #11
                      It was asked on audifans about the door adjustment.
                      This is a grey area "until now"
                      What do you do about getting to that outward facing bolt? Hardly going to remove the wing.

                      Problem solved.
                      There is a sure fire way to get to it without the wing coming off if you can't get an offset spanner in the gap between the door and the wing, then get enough leveredge (sp?).
                      Remove road wheel, remove arch liner then the rear plastic trim you'll see. The plastic bit I refer to is sort of a filler piece between the outer and inner wing at the rear and is attached with one 8mm hex head screw in the centre and by removing a pozi headed screw on the rear bottom edge/corner of the wheel arch.
                      Once that is gone, you can get a 13mm socket on a ratchet or a 13mm spanner and loosen it off. Remember to temp reattach the wheel and lower the car to the ground while actually adjusting the door.
                      Might sound like a pain in the butt, but removing the arch liner is a piece of cake really, all the screws are into plastic insert nuts popped into the main bodywork. No rusted together fasteners etc.

                      I'll try and get a picture of the plastic piece I refer to, and where it is on the wing I took off..





                      Ok, you are saying, I've got a Coupe though, is it the same?.
                      Yes it is. The Coupe has a very similar piece and it's secured in exactly the same way.
                      2001 Avus Silver B5 RS4.
                      2004 A4 Avant 1.8T quattro Sport-LE.
                      1995 S2 Coupe - sold (sniff)

                      Comment


                      • #12
                        Sunday gone (02/03/2008)

                        Well, as usual our great climate called an end to the day. Has been spitting on and off all day, but progressively longer and heavier rain spells put an end to play.
                        Managed to get the whole front end and the whole drivers side done, apart from the rear bumper as I'm not touching that. A nice S2 avant rear is on it's way.
                        Started making progress down the passenger side, but half way down the passenger front door I had to quick sharpish stop and pack away as the rain was getting too heavy.

                        Used a whole green Sonus clay bar and nearly a litre and a half of Megs last touch as lube, the most tar spots I've ever seen, There were tar spots on top of tar spots and all other manner of bonded on contaminants, mainly on the lower flanks.
                        Just about destroyed one Lake country 3" cutting pad so far, even though the Menzerna Intensive Polish is good stuff, I still had to do three rounds on each panel before moving onto some Menzerna Final Finish compound on a 3" medium pad, the paint was that scratched and oxidised.
                        Haven't had time to put any LSP on (last stage product) but I'm on late shift all week so I can get a good bit done each morning.
                        The drivers door as said previously, looked a slightly different colour. I thought as it had obviously been sprayed along with that old wing, that it had a clear coat on top as it wasn't faded like the rest of the car.
                        Nope, it's a flat colour too, and after spending what seemed an age on it, it's come up a lot better than I thought. Still ever so slightly the wrong shade, but I think for the time being I'll leave it as is.
                        The bottom leading edge of the bonnet and both headlamp trims were a PITA too. I may remove the headlamp trims and rub them down and repaint. They came up shiny, but have a LOT of stone chips.

                        Ok, pictures, Tried to keep them in some sort of order. I'm well chuffed with the colour match of the new wing and bumper to the bonnet and the nearside wing. Well happy with it.
                        REALLY needs some alloys, ANY alloys as long as those black steelies go. Amen.










                        2001 Avus Silver B5 RS4.
                        2004 A4 Avant 1.8T quattro Sport-LE.
                        1995 S2 Coupe - sold (sniff)

                        Comment


                        • #13









                          Still very much a work in progress, but I'm so far pleased at how it's coming along. A fruitful if wet and windy weekend.

                          And that's the project now up to date.

                          Jas..
                          2001 Avus Silver B5 RS4.
                          2004 A4 Avant 1.8T quattro Sport-LE.
                          1995 S2 Coupe - sold (sniff)

                          Comment


                          • #14
                            Planning ahead to the badging on the rear of the car.

                            New "Audi" badge bought for the nearside, new rings for the centre and new 1.9 badge for the offside.
                            That left the TDi part which I thought I'd change to something a bit different.
                            The car certainly in no way deserves a red "i" but seeing as it's a bit more green than a usual diesel with it's veggie oil power, I thought a green "i" would look quite cool.
                            So purchased a TDi red i badge in the correct font, and will paint the red i green.

                            This is the one I purchased, messed around in a paint program to show you how it'll look.



                            Also a picture of the five spoke 17's I have, Have been offered four tyres, new but a budget make, for not a lot.
                            Still can't decide if I like them though.
                            They are polished and lacquered.
                            Maybe a bit bling. Will try them on one side of the car and see what they look like.

                            2001 Avus Silver B5 RS4.
                            2004 A4 Avant 1.8T quattro Sport-LE.
                            1995 S2 Coupe - sold (sniff)

                            Comment


                            • #15
                              Nicely going! Very brave to "restore" that beaten 80. The fog mistery is crazy! Any changes to the rear? competition spoiler?
                              RS2 Black - stock 315 HP
                              RS2 RS blau - stock 315 HP
                              Sport Quattro - 1005 HP
                              High Octane website

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