My S2 coupe bit of a rebuild and repair thread.

[B5NUT]

Few job done over the the weekend.

First off find a good position of the microphone. Found a nice little place in the interior light cover. The microphone is clamped in place using a trim clip from an A6 and and used an iron to melt the top section in a couple of places so it would not work it's self lose.
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Also cut a small section from that area so I could fix the right hand side spring clip which had been snapped off at some point!
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Also re-tensioned the alternator belt, was getting a bit of squealing from the belt. It was fine for the first few days, just started to happen over the last couple of days and was getting worse.


Next job was to fix another issue caused by the screen fitters. The lower water deflectors no longer fitted properly, and were rubbing against the wipers. Once removed the issue was found. Massive about of screen adhesive stuck to them.

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This was the excess adhesive removed from the trims, it was about the size of a golf ball.

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Gave a area clean up. Also before I removed the wipers I marked up the position on the screen using the masking tape.
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Also fitted new wiper blades as the old ones where hard has hell. Just fitted standard Bosch wiper blades front & rear.

Have a question for anyone still running standard brakes. I've fitted Brembo all round (Front disks are zimmermann as Brembo is NLA for the discs) So after a week of driving the car around, and to be fair I'm still taking it very easy the front wheels were covered in dust. Now this could be the coating zimmermann apply to there discs but it's very black dust so don't think it is.

This is the first time I've used Brembo pads, and was not expecting this much brake dust. Is this normal for Brembo pads?
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Inside of the wheel is thick with dust
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If this is the amount of dust I need to remove from the wheels every week I will be looking for better pads. This reminds me of the Pagid pads which were awful for giving off dust. I thought Brembo would be better that this.

Also I got the dreaded Brake Bomb light and beep on the car this evening! Brakes and steering felt OK, there was no loss of brakes or steering, and I did not have to press the brakes any harder. So after a fair bit of reading I filled up the PAS reservoir to the max and the light went out. Are these sensor caps a know failure?

[B5NUT]

The body of the frame is OK, it's just the edges that have corded away. It's metal after all so it should be repairable. If not then the frame goes in the bin and I'll keep hold of the glass.

[sidrick]

You're a braver man than I

[B5NUT]

Fitted the replacement sunroof panel today, as it stopped snowing for while.
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With the old panel removed, I separated the glass from the frame. It's not in the best of condition but I think it could be saved with a bit of work.
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Glass is in good condition, but the rust has scrapped away some of the coating that will need to be repaired. No idea what sort of coating that is, so will will have to talk with some glass companies.
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[B5NUT]

Thanks. I want to try and save the one on the car even if it does require some welding and new metal. The glass is in one piece so I hope the frame can be saved.

[newsh]

You’ve done well to save the glass roof, they’re a rarity now, mine had one but it was rotten and the glass was flapping about and I chucked the whole thing and fitted a tin one, then another tin one! Lol

[B5NUT]

It went 97% well.

First minor issue was the top rubber trim does not go all the way to the edge on the drivers side
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The side trim on the drivers side is not seated correctly, they are coming back out to sort that
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Finally also on the drivers side the interior trim is also not fitted correctly which I will sort out

The glass fitted was manufactured by Pilkington as figured. I guess all the Audi branded glass (make by Pilkington) went long ago.


While I'm on about glass the sunroof glass was bonded to the frame this afternoon, it's not the nicest stuff to work with and it goes off quickly. Also I wish I have another 4 clamps. but hopefully I won't have to do it again unless the other roof can be repaired but I think it past saving. I'll take that one apart once that panel is back in the car.
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[LHD_Kid]

Well...... how was the screen job?

Breath is baited.....

[B5NUT]

Hopefully pick up the car in the next couple of hours. Finally got all the parts sorted to rebuild the sunroof.

Spent the best part of 2-3 hours removing all of the old sealant. Not sure if that is 100% required but would rather have it as clean as possible
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Found these blades best to remove the old sealant, used about 5 new blades in total.
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Received the adhesive to glue the frame & panel together. I got two tubes of the adhesive just in case I muck things up.
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Got the parts back from being blasted and powder coated.
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Will glue the frame together later today and and get it fitted on Friday or Saturday as the weather forecast does not look good for the next couple of days.

[B5NUT]

Autoglass still have the car. Was told it would be ready for 1pm today then got a call later saying the wrong rivets were supplied with the job, so would be ready for 10am tomorrow.

[fish]

How did you get on with the windscreen?

[psiconauta911]

It is looking awsome!

[B5NUT]

Had the alignment done on Friday and it's OK! However they only really looked at the toe setting and never touch anything else. So won't be using them again! Anyway the values are not that faraway from the factory settings and I've booked in the Automark to have it done properly in 7 weeks time.

So with the alignment done ish! Lava Heat Wrap was wrapped around the manifold and I fitted the refurbished injectors (Thanks to LSG). With those jobs done I called it an end to the car being off the road and started driving it for the first time in 5 months. So far I've done over 120 miles this weekend and the only fault I have with the car is one of the front ABS sensors is not working correctly, I get an intermittent fault code about speed discrepancy for one of the front wheels and low speed braking I can feel a slight ABS pulse on the brakes (Tyre pressures are 36PSI all wheels). So will look for 2 replacement sensors.

I did also have another issue which I fixed as the bodged Exhaust system was able to touch the prop over rough roads. So that was slightly modified so that no longer happens but it's going to be replaced as I'm not happy with the system.

Today was the longest run. Just over 50 miles. A trip out to the seaside with my daughter who thinks the car is far better than my last A6 Avant.. She is right about the S2. It is far better It puts a smile on my face. However I'm still a little on edge with the car as I keep looking for issues and looking & hearing for any problems, and wondering if I've made any mistakes with all the work I've done on the car. Think it's just a trust thing and I'm sure will improve over time, and once I get to know the car.
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The other Issue I still have not been able to fix is getting the low speed fan to run if I press the AC button. My temps are fine it creeps just above 90 while idle in traffic and you can feel the fan kick in, so it's all working as it should. However I would like to fix this fault. Going to buy some replacement relays as I read that could be the issue.

I also need the aircon working in this car, so that's a job for next month as I'll step up my search for AC parts.

A job I have done over the weekend was to fit the new Radio. Found an new Pioneer unit on FB market place. I was looking around for this unit but it was out of stock everywhere. Also the FB seller was £60 cheaper than Halfords. It's a Pioneer DEH-S720DAB DEH-S720DAB - Car Receivers | Pioneer (pioneer-car.eu) Not what you call OEM looking but it's a nice unit which has dual BT, BT music streaming and DAB.

Only issue I had was mounting the DAB aerial, and I'm still not happy with the look of it. I was hoping you could mount the plastic box under the trim panel, but I could not get a good signal. You also need it to be grounded and it does not have a ground cable just a daft foil stick on strip (one that is black) what I had to make a plate as there is a rubber seal that goes all around the side window.
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Once the upper B pillar trim is fitted you don't see that plate
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Also had to make an extension cable, as the DAB aerial only comes with a 3 meter cable as it's kind of designed to be mounted in the front window. That would do my nut in looking that that box every time I got in the car. Thankfully had some fakra parts and cable from my retrofit days so made a small extension up.
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Still it's now in and working, just need to push it back in place once I fit the microphone as I ran out of time.
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The big one tomorrow is the windscreen replacement, just hope they got the correct screen this time. Have to say I'm a little nervous! I got the lower trim piece but was not able to find the upper one so they are going to fit a generic trim part I will ask if they can salvage the old one but almost sure they wont.

[newsh]

Looking very tidy now!

These a tweak you can do to the seat mechanism, basically it’s simply filing an extra tooth on the height adjuster to allow the seat to drop a little further. Otherwise you could also reduce the thickness of the foam squab, would be a shame if it’s in good condition.. I’m about 6’4” (was 6’6”when younger!) I find the coupe pretty roomy, much more so than the Avant.
I’ve tied a couple of seat options, original 3B seats, ABY seats (slightly higher but maybe because they’d done less work) some E30 seats on Recaro sliders (very low indeed, could wear a crash helmet with these in there) currently I have cabby electric Recaros which are super comfy and look right in the car.

[B5NUT]

Thanks Kit. I did not think there would be any solutions to either problem. I do wonder if the A4 B5 steering setup would fit, however it's not in keeping with the factory options of the car so I will just have a pay around with the seat position. I'm 6ft and have very short hair so it's a little irritating, as it's like a short hair brush rubbing on carpet! I've got the seat back a little which is helping but will keep playing around.

The noise sounds like it somewhere around the hvac system, will stick me phone in there tomorrow and record the noise. However it could noticeable because I have the radio removed and there is a big hole in the dash. It could be normal noise of the car, as the list time I had a drive of the car was October.

Gave a car a wipe down and clayed it today. It's comes up well, but there is still a fair amount of crap on the paint work. Going to wet sand the car at some point and polish it up. That's the first time it's be cleaned since I got the car.

This is also the first time I have really driven the car where I feel it's all working as it should be. I got the car October 2nd and less than 3 weeks later it was in bits and off the road.

Now that it's cleaner the wing has a better colour match.
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