My S2 coupe bit of a rebuild and repair thread.

[B5NUT]

Got some of the fuel pipe parts over the weekend. As recommended I went for the Cupro-Nickel pipe, also already had some 8mm id fuel pipe from rebuilding the A4.
1-fuel.jpg

As I'm still waiting on further tools & fittings for the fuel pipe it's on with the brake pipes

The pipes were in overall OK condition but as you can see from later images they were not in the best of condition.

For the brake pipe I'm using the same stuff as VAG uses at the factory, was given 4 roles from the same VW garage that got me the bolts.
3-brake.jpg
With the pipe straightened out I put the flares on using a vice mount tool as I found the hand held ones a little hit or miss
2-brake.jpg
Once the end's were on it was time to bend them into shape using a cheap pipe bender, but it does the job very well.
4-pipe.jpg

Pipes may need a little fettling when fitted to the car, but seeing as this is what I had to work with in respect to a template I think they have come out OK. Looks like they have been removed before and been kicked around the workshop
5-pipe.jpg

[Laaf]

What's the part number on the break line piping?

[B5NUT]

Anyone know if it's possible to replicate this if I buy a hydraulic crimping tool or am I best just using double ear hose clips?
1-connectors.jpg

[B5NUT]

What's the part number on the break line piping?

Part number is 111 611 998 it's about £13 for a 4.7 meter length

[B5NUT]

Tool & connectors arrived today
1-parts.jpg

Been told that I may face issues with the stainless steel compression fitting. Never heard of PANAM fittings before but they look good quality, and appear to have 2 olives that will clamp to the pipe. Anyone used these before?

2-pipe.jpg
3-pipe.jpg
Also still having trouble getting any information on these clamps, guess I'm going to be stuck using double ear hose clips.
1-connectors.jpg

[Tractor Dave]

Ooooh! Nice pipe straightening tool.
I just used my legs

[steve briance]

Re your question on crimping the flexi (fuel?) hose, why don't you visit somewhere like Pirtek or similar and get them to do it. If you spend the time sourcing the banjo unions from somewhere like Merlin motorsport or Demon Tweeks then all you need from Pirtek is some suitable hose and 2mins crimping time.

Im all for buying tools but ive never needed a hydraulic crimp and can't think i ever will when i don't find myself making hoses every week.

[B5NUT]

What I'm not getting about the fuel lines is the pipe going from the tank to the filter. If this is under 6 bar of pressure these joints appear to be very poor! Or does pipe look to be some after market job? As it's got the screw fit end at the tank and cannot believe the garage that made a bodged job of the pipework had anything to do with this pipe.
1-joint.jpg
2-Joint.jpg

So while I'm still thinking about the fuel pipes and how to make them, I got on with fitting the new brake pipes I had made, as it finally stopped raining and it's nice and dry.

Offside pipe fitted without much issue
3-brakes.jpg

Nearside pipe was a complete sod and had to remake it 3 times before I was happy with the fitment and wanted to make sure that it was not touching/rubbing against the chassis
5-pipes.jpg

For the most I just cleaned and reused the clips but some where damaged and replaced. I also just cleaned up the old distributor as it was still in very good condition
6-brakes.jpg

Pipe to the front of the car is a little wavy, but that's the best my pipe straightener will do
4-brakes.jpg

Then replaced the original connecter that Audi used and fitted a female to female union.
7-pipes.jpg

So today I will be hand sanding (going to give the grinder a miss on this one) the filler neck and a quick spray with epoxy to get rid of this rust, before it's refitted. Then I can start on some of the fuel pipe runs. I've got a funny feeling I should have purchased 2 roll's of pipe, as I'm sure I'll muck one of the lengths up.
filler neck.jpg

[Tractor Dave]

Yes, that is the oe pipe and yes, you will need two rolls if doing all three lines front to back

[B5NUT]

Found more rust on the tank around the connectors so that also had to be stripped back.
1-rust.jpg
2-rust.jpg

3-paint.jpg4-paint.jpg

With the rust all sorted on the tank I was going to fit it into the car today but found yet more rust! All the area's painted in light green epoxy had either paint rubbed away or rust was found.
5-paint.jpg

Main area was the near side corner, it was mainly surface rust and bubbling paint. It's not a nice finish but it's not going to be seen, and it's now well protected. At some point I will look to spray the entire boot area, and get a far better finish.
7-rust.jpg
6-paint.jpg

[Tractor Dave]

Now is the time to relay your fuel pump! It's well worth doing whilst you have access.

[B5NUT]

Now is the time to relay your fuel pump! It's well worth doing whilst you have access.

Never heard of that mod before

[Tractor Dave]

Never heard of that mod before

https://forums.quattroworld.com/s4s6/msgs/24327.phtml

The original feed wire is long and thin.

[B5NUT]

Are you doing this mod to your S2?

[Jaswan]

Relaying the pump is more for safety and reliability. The OE wiring gets hot and then fails.

For the banjo on the fuel line you could get the fittings and make a short flexible piece. Have a look at torques fittings on eBay.

Jase.