struikie - Audi 80 B4 quattro project

[struikie]

Got the fuel filter holder I designed today. 3D printed in ASA. Put in place and
made the hose from the filter to the rail. It feels good putting things back on!




Also had the fuel pump tool 3D printed in PETG.


JW

[struikie]

Put the front suspension back on today.









The aftermarket fender liners (van wezel) fit like crap. Anybody have experience
with a better fitting alternative?

JW

[struikie]

The fender liners are thermoplastic, so a heat gun does wonders ;-)

The bolts for the caliper to bracket weren't available in a galvanized version, so I got a DIY kit.









While I was at it, also did the bolts for the brake pads.



Put the discs, calipers and pads back on.



Was a little bit confused by the fact that the brake hose was very long. When
I first fitted these brakes I had ordered black lines. That one was too short.
Ordered new (longer) ones, but got clear lines.
In the end I think I swapped the brake lines that go around the damper from
left to right. So now I could fit the black lines I originally ordered.

JW

[struikie]

Designed and had some parts 3D printed in TPU rubber.

Caps for the slots in the rear suspension mounts. Through the slot
I can access the damper adjustment without the need to take it al apart.






Ring on the front suspension cups.






Covers for the front strut mounts.


Fuel line rubbers for feed and return line.
I am ditching the evap.








JW

[ert]

The bolts for the caliper to bracket weren't available in a galvanized version, so I got a DIY kit.

As far as I know 10,9 and 12,9 bolts aren't supposed to be galvanized.

[struikie]

Good point because of hydrogen brittleness. I have enough spares left.
You can plate them, but have to bake them after. Even then it isn't guaranteed to fix the brittleness.
I'll have a think about this.

JW

[struikie]

Treated the rear wheel wells with the Dinitrol 447.





Next up is cleaning the gas tank and fitting the Walbro pump.

JW

[struikie]

Wrestled the pump out of the tank. Broke the 3d printed tool but managed to
still use it by drilling two holes, sticking a 1/4" extension through it and using a
27mm spanner from the top driven by a stick through the ring end...

Got the remaining fuel out of the tank with a Pela vacuum pump. Not much
crap to be seen in the tank.

Cleaned the outside a bit. Need to finish that later.


Put the Walbro pump in the basket. Need to get a suitable hose clamp and thinking of buying a new
connector instead of reusing the original.


What do we think about the cracks around the outlet connection?
It's two different cracks from the front and the back.




JW

[Tractor Dave]

The cracks are common. If its not leaking, don't worry too much. Support the banjo with mole grips of plumbers wrench when tightening and removing the nut.

[struikie]

One clean tank.


Crimped on a new connector for the pump.


I suspect this connection is sitting too high. Ordered a banjo style fitting.


JW

[struikie]

Walbro 450HP in place.


I think the return lines inside the tank got orientated differently over the years.
When the cover is lined up correctly, the notches line up with the gaps in
the return connector. No possibility of rotating one side 90° so fixed the
connector in place with a tiewrap.




Removed the evap system. Put a checkvalve (allowing air out) in place.


Made the fuel lines.


3/8 cunifer into AN6 PTFE.


Put the front wheel well covers in place.
Put the rear bumper back on.
Cleaned the exhaust system.


JW

[struikie]

Happy that I managed to snag a correct under body tray.


Wrestled the fuel tank in place. Had to massage the new stainless tank straps a bit here and there.
Finished the fuel system.














Tomorrow I'll try and fit the subframe.

JW

[Jaswan]

Well done!

Looks a really tidy job you have done

[struikie]

Some progress today.






JW

[struikie]

Put the diff back on.


New brake line.


Put some thicker wires to the fuel pump in place. Used the original wires
to switch a 30A relay. Will need to tidy things with some cloth tape.
The Walbro can draw quite some current. This would have fried the original
1.5mm2 wires for sure...




Ordered new black Goodridge brake lines to the S4 calipers.


Couldn't resist checking out how the new wheels would look.
I think I made a good choice!


JW