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Still no work done on the coupe as i am FINALLY getting to my mill. The learning curve has been vertical but i got the first side of the urs brake caliper adapter done yesterday. This was the second attempt as on my first, the clamping failed and i returned from the grocery store with it on the garage floor......
One thing this experience has revealed: we pay a hell of a markup on BBKs. The raw material cost me just under $10 each cut to length. I got 6 of them anticipating screw ups.
my only other observation is holy crap this makes a mess! Especially with coolant. My machine is not enclosed but boy to i need to do something about that. The front corner of my shop is now treacherous as i woke up to it reading -25 outside. Not the greatest seal on the door so all the coolant spray has frozen on the floor....
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In coupe relevent developments, wives are funny.... as of the temporary shelter's demise, i have shuffled the coupe into the house garage while i work on the urs in the shop. My wife really hasn't seen it before. Had a chat yesterday and it went sorta like this: "i've never really seen that car before, it's actually quite nice, are you still painting it white?"
suddenly she's all invested in colour selection lol.
i'm hoping to have the urs brakes sorted in the next few days. Maybe by the weekend i have shuffled cars again and i can get back to work on this.... if i have 2 blanks left, i may just make the 17z adapters for this too.
Well, i've burned thru 3 blanks but i have one of the urs adapters made. Fits well too. Hopefully the second will be done tomorrow and then i will be able to swap s6 with coupe in the workshop. Still learning on the mill. Much crashing, endmill shatter... such fun lol.
Finally getting some numbers back from bodyshops for painting the car. $10,000 starting....
A buddy said he could do it at my house for 1000 plus supplies, which will be around 3000 nowdays. But the product would be lower qualityfor a host of reasons. plus he's got all kinds of things going on which makes it hard to get it done.
These numbers are a lot higher than i thought they'd be.
maybe i dive back into the fun greasy stuff and go straight to 2.7t....
Edit: it gets crazier. In these parts, it's widely acknowledged the audi dealer has the best bodyshop in town. 15-20k and they are booked till next spring.
now, that would be a better than oe result but damn...
but if i decided i wanted to knock this outta the park???? Let's go find an a6 2.7?????
The man math at work here is that DIY in my garage is a good chunk of change no matter what so maybe the lower quality is not worth the savings..... so, maybe a pro is actually worth it.
Last edited by ottawa coupe; 18 March 2025, 14:50.
Got someone coming by to look at the car on monday to get me a quote. If i hqve time, i'm hoping to bring it to another shop so they can look at it too.
Got the mill working again so i am back to making brake adapters. Getting better at it, i need to write down a checklist though as there's a few things that fusion automatically puts into the program that i need to take out or bad things happen, like after the program ends, it tries to drag my $75 carbide bit through the part and bends it . I really need to get the limit switches working
Now for developments on this actual car..... lack of sleep is bad for the creation of bad ideas. I have an old vems for my s6. It bricked and i am going the speed density motronic route for that car now. The AAN is sequential ignition and injection. The AAH is sequential injection but batch fire ignition. Meaning i would only need to ensure the vems has the one extra channel to run a 6th injector to get it working on the AAH. Get a coupla k03s from some 1.8ts in the scrap yard, weld some pipes together, make a cheap 250/300hp??? Surely even the stock rods could handle 50hp/cylinder??
I mean, it would probably add a year to the project but could be fun??? Besides, this'll feel very slow in the face of the 400hp the s6 is about to get???
So i have been chasing down answers and poking around sale ads and ebay listings....
The whole ghetto 12vt is actually not terrible lol. Turns out the 12v bottom end is quite stout? And could easily absorb the max 300hp i'd chase. 2.7t mls head gaskets appear to fit so i could stack multiple inner layers up to drop compression into the 9s. Ghetto AF but i did it with a 16vt racecar running 25psi for years. A spare engine harness is all of $100 on ebay and there's a guy literally 5kms down the road who's got a pair of b5 s4 turbos in decent shape for $150.
All i would need to figure out is what is wrong with my vems, deal with the 6th injector channel and get a second o2 input sorted....
Very tempting cheap thrills lol
We'll see what next week brings in terms of paint quotes and timelines.....
got the license plate light sorted from someone down south. It works great. I THINK i have everything sorted such that upon reassembly i will pass safety inspections.
Tomorrow i get someone coming by to look at the condition of the shell to the aim of getting a better quote for paint.
I was SO close to finishing the brake adapters for my s6 but then all of the 30yo electrical decided to pack it in on my mill. So going to find the bottom of that rabbit hole and build a whole new controller and replace the remaining steppers. I got a taste of making stuff i want and now i want more lol. 17z adapters for this and some sort of seat mounting bracket are on the short list of things to make. Maybe 12v turbo stuff gets added once i am up and running consistently lol.
Well, 20vt related but not coupe related. TTE 420 arrived for my s6 today. The chips from efi motorsport are at the post offic for collection tomorrow. Last part of that puzzle is the turbo inlet boot which was ordered today (because i just realized the oe one wasn't gonna fit lol). My neighbour who is well versed in circuit boards and soldering stuff i have a hard time focusing on (lol) returns from vacation next week. So that'll have 400hp by the time all crappy weather has passed us.
Coupe work still delayed as in the end i have had to completely overhaul and update my mill. The electrical parts were letting the smoke out one at a time. All new steppers, drivers, power supplies and control board. These brake adapters are turning out to be VERY expensive lol.
At any rate, i hope to be back to building the rear seat delete next week and finalizing the paint plan shortly thereafter.
I am FAIRLY confident that upon completion of the rear seat situation, i actually have all the things i need to get this thing to the finish line.
Well, 1, the chips didn't arrive yesterday. It was the rear bulb trays that i really never exoected to get here. If you'll recall (cuz i didn't!) They were quickly bought on ebay before i realized they were coming from Ukraine..... 3 months later.....
But in new relevant to THIS project.... even more scope creep isn't gonna happen. I sat down and really tried to force my AAN vems back into life with the idea of maybe doing a ghetto 12v turbo on the cheap. It was not to be. It refused to wake up and talk and i'm not going to spend money getting it fixed when i can find whole allroad 2.7ts for under $1000 if i really wanted to.....
Unbelievably, i actually worked on this tonight! Life and work are both incredibly busy right now so i'm only getting 30mins here or there....
Over the past couple of nights i have managed to make the bottom part of the frame for the rear seat delete. The tricky part now being how to set the height to ensure the finished product is a flat floor. Being the simple man i am, i happen to have lots of lumber kicking around i can use to work off of lol
It would be nice to think i'll get the frame done this weekend.
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still trying to work out paint. It's not looking good....
Right, got braces in that are flush with the 2 frames and some mounting pads welded to the bulkhead between seats and trunk. I need to finsh weld and clean it up and add some tabs at the front for the rivnuts that will hold the cover down. Here's the general idea of the goal. Need to secure the battery tray from the cabrio yet.
That's bang on Jase, the prices for these parts has dropped to the floor so Ihought I'd see how manfcturing in the far East has been progressing in past two years.
They must pay their staff in bowls in the great empire run by Winnie the pooh! How one they can now produce quality parts for very lille moneI that it's actually being backed up with proper testing and results on YouTube.
I've actually now have a T3 flange manilfd so can attach that GTX35 blantant knock off. That's from another manufacturer but still Chinese and a it's a propper tidy, complete with all gaskets and even a bag of a dozen M8 exhaust nuts.
I've decided to put the S6 seats in my rat 80 as I'm cutting that car about anyway, the interior isn't there to catch fire. Plus it a straight forward itinstallation involelding welding nuts to under side of the seat runners.... A bit of a faff but as fitting seats from another platform goes very easy. The rest of the linterior will fit the A4 rear with really quite minal hassle. That's quite a rare car and I haveI hopes of spotting an affordabke replacment one on eBay. As the fronts are still so good I'd like to keep it original I'm go to get a couple of quote to repair it m, will also have my C4's drivers seat back side bolster than wants doing now before being driven as foam material is undamaged
I did lash out a Sealy bumper repair kit It seems there is no middle ground. There's no middle ground either a really cheap and will probably cause a fire and the one I have which had been used once and was much cheaper than a new one.
Also got an other of the 1/2 inch drive guns I got at Christmas time as well as a drill. I've have just used it since as one can insert 1/4 drive head's into the face of the hard. It's covered in oil and been dropped a coupe of time's and it's still undo everything I've been working on. The drill is pretty much as good as the original, plus I thought to give 9AH batteries. The grinder eats 5AH one in miutes so they'll get tested next time I use that too.
And I also thought I'd give one of the Dremmal copy's a go aa I've had such good luck with parts so far. The one I got was less than £30 and has a porting attachment which is what swayed me
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1990 B3 2.0 80 quattro.
1992 C4 2.8 Avant quattro
1994 RS2. MTM 380 BHP Conversion.
1999 B5 TQS.
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. I really need to get the limit switches working 
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