95 S2 Limo Replica

[sjw185]

When I had the struts off found the front bearings had a bit of play, but had a bit of bother getting replacements from local motor factors.
After a couple of attempt to get the right ones found on the forum best to get ones direct from SKF so that's what I did and ended up cheaper than my local place.

After pressing the bearings in at my mates work got struts reassembled with new top mounts and reassembled brakes with HEL lines.
Refitted old disks and pads right now as car will be stored outside in poor weather but will renew for MOT.
After bleeding brakes there is a fair bit of travel in the pedal so will need to investigate hope its just linkage adjustment.
Went to move car out of the garage and found it was leaking fuel down on to gearbox and near exhaust.
Flexible lines have been chopped to remove the original crimped connections and think with me moving lines for vacuum servo they have started leaking from flexible to copper connections as held on with Jubilees.
To stop the leaks and remove perished rubber decided to get some AN fittings from rail to under the car to prevent the whole lot going up in smoke.

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fuel lines.jpg

[sjw185]

Update

Refitted exhaust with a flexible section and a 200cell cat.
Need to work on my welding skills but its stuck together for now.


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With 3b track car up on the ramp I set up the limo on axle stands to remove front suspension and subframe.
All the bolts came off ok and with gearbox supported underneath got the whole lot out without much drama.

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Once removed stripped all components down for treating and paint.
Ran out of gas for my blow torch and had the mig welder rigged up with fluxcore wire as I was repairing railing outside my house so
thought I would give it a go.
Worked really good and made bush removal easy.

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After some buffing and rust treatment subframe didn't look as bad and still had some original paint left.
Had another subframe that I was going to treat and swap over but good job I decided against it as gearbox mounts were different.

Got everything painted using Por15 and fitted verkline subframe bushes.

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[sjw185]

Some good work done there..
Any progress lately?

Yea got some more done will post up some pictures soon.

[80Comp]

Some good work done there..
Any progress lately?

[sjw185]

Cut the nobbler off the booster, the shaft is 10mm so cut a 10 x 1.5 thread which is the same size as the original clevis.

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[sjw185]

Found a A8 vacuum booster in my shed.
Gave it a try to see if I had a bit more room with my intake pipe as it has a sweeping bend but made little difference.
Was looking at cutting the bulk head to maybe sit it further back but thought that would just create more issues.


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Then I thought about remote mounting the reservoir or creating extenders to mount it alongside.

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Ended up with this one below from a VW Golf seems to sit in very well with one brake line coming in from each side.
The brake line underneath the intake pipe is close to back of the master cylinder so it has good clearance.
Vacuum and clutch hose are in a good place also.
Only bad point with this one is the level sensor shoots straight up and with the tall reservoir its almost touching the bonnet underside.
Can maybe adapt the cover sensor or replace it with a Audi one that has the connector on the side.

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The orientation of the mounting holes is mirror image so ultra engineering is going to make an adapter and see how it fits once solid.

[sjw185]

Nice body colour, will be a nice "S2" Saloon. Thanks for sharing your work and the photos for everyone's benefit - i.e. referencing / enjoyment.

Best wishes for continued progress.

Thanks,

Yea it's a nice colour hopefully a lot of the panels can be restored by cutting and polishing.
Need new wings also.
Had my set of 17'' mk2 Avus redone before the lock down which I think will look sweet.

[macspring]

Nice body colour, will be a nice "S2" Saloon. Thanks for sharing your work and the photos for everyone's benefit - i.e. referencing / enjoyment.

Best wishes for continued progress.

[sjw185]

Fitting S2 snub mount and removing V6 item from below




Old 3b hose

[sjw185]

Before



After

[sjw185]

Yea got some more stuff done.
Finished up rear subframe and connected handbrake cables.
Removed intercooler setup to fit original crossmember and ABY intercooler.
Mixed and matched old boost hoses to get me going.
Fitted a flexible joint and a 76mm cat to the exhaust.
Not managed to upload any photos to the forum for some reason?

[quattroamm]

Any more updates

[sjw185]

Looks like a nice S2 lurking in the background?

Yea belongs to forum member as2q helping him get it ready for MOT after a few years in storage

[sjw185]

Tried the hoover with a wee hose but I think ive already got all the loose stuff out and I am left with the a few crushed bits that wont shift.

Resorted to brute force and swearing loudly but no joy.

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After all the fighting trying to unlatch the rear seats they just opened all on there own
The release oil must have worked its magic.
The bigger side needed some additional work as I bent the level when trying to force it with the spanner.
It was unlocking but the latch was not clearing the fixed pin.
Once I figured that out and bent the bar back its unlocking again.

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[Tractor Dave]

Looks like a nice S2 lurking in the background?