Pearl white coupe revival

[ottawa coupe]

Lol, no worries!

Can't delete but no big deal

[ottawa coupe]

So, after many small details and one big one, my s6 is driveable once again. A couple faults to work out over the course of the summer. So that means the coupe is back in the workshop.

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As a result of consultation with my wife, i think i need to change the title of this thread. The colour will be some form of dark metallic purple.

I progress will not speed up however, the list of outdoor house work is huge and the first thing i need to get to in the shop is FINALLY fixing my cnc mill.... the wife and i need to go to the paint supplier and come up with a colour and then i need to work with my friend to get it prepped for him to paint. That's the real show stopper, i can't heat my shop enough for paintwork so realistically, i have at most a 3 month window to get it done, or i lose another 6.

[ottawa coupe]

So, the cnc contunues to frustrate. Havin a hell of a time figuring out the spindle driver i need letalone finding one....

so that means in the next week or so, we're gonna figure out the colour.

In the meantime, given how much time has passed and how much i have changed, i figure i should take a coupla weeks to do an initial dry run on the rebuild. Just laid the harness in. I suppose i should remove the hood and hatch tho...

The cool weather has stayed far longer than normal this year, good time to do this type of work....

[ottawa coupe]

Well, good thing i'm test fitting the wires now before paint. Turns out the holes in the firewall are different sizes between the b3 coupe and b4 cab. I used the b4 harness as my base as it was in far better condition so the grommets don't fit. Not sure what will be the bigger pain in the butt, open up the holes or replace the grommets....

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[dr.strangelove]

Looking good! Check/replace that steering damper before you put everything back in the bay.

[ottawa coupe]

Hmm, i have resealed another rack that i will use in the final buildup, probably wouldn't be a bad idea to track down a new damper while i am at it.

Got a chance to take a peek at the firewall situation again last night. Confirmed that, even if i am not using the correct holes in the firewall, they aren't big enough in some cases. The solution will require the creative use of hole saws i think. To be resolved this weekend i hope. The other wiring issue to work out is the main positive lead thru the frame rail. NA coupes do not have a hole in the rail for the wire. I need to figure out where to put it and drill it out....

Any pictures of that hole and where it is would be greatly appreciated!

[ottawa coupe]

And it comes into tbe car thru this hole? 20250628_140309.jpg

[ottawa coupe]

Well, the cheap bum that i am came up with a win today i think. Had to figure out the positive lead thru the frame rail situation. Namely, wire. Settled on 4awg as that's what is used on the cabrio. Everything i was seeing was gonna be well over $75 for 10', which wasn't enough.

Here's a cheat code guys. 16' 4awg jumper cables for $17. So really you're getting 32'. Nice n flexible and because jumper cables, the insulation is extra thick. All of the ends arrive monday. Win!
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[ottawa coupe]

Well, another great plan goes up in smoke....

While parting the cabrio out, i took great pains to removing the carpet in 1 piece as it is of much higher quality that coupe stuff. I was not aware that the floor pans are different and the rear seats are further forward in a cab....

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It's a good thing i took that black coupe carpet in my tour de new york last year.....

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It's not nearly as nice a carpet though and i have no insulation for it whereas the cab one has foam moulded onto it. Another thing about the cab carpet is that it has a gap in the passenger footwell where i was going to put my battery positive junction point.

Not sure what i will do yet. I need to look at the center console, maybe cut them under the front seats and join somehow?

[ottawa coupe]

Is this a b3 thing or is the a planted seat bracket thing??

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[ottawa coupe]

So, rough draft of the interior done. First lesson learned is that b3 seats aren't centered on the steering wheel....that's just how it is, deal with it. So i have centered the boxster seats as best i could and welded tabs onto the planted seat bracket to make it all work.

Because the mounting points in a boxster are level and the seat base here is tilted back, the seats are somewhat more reclined than they would be normally. I'm a tall guy though so it is more important my butt's down low. I may be able to further modify the base at the front though.

As for the carpet situation, i have recreated the false floor at end of the passenger footwell from the b4 so i can put my battery positive junction point there.

I have cut the cabrio and coupe carpets beneath the seats and will figure out how to neatly splice them later.


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And, if all goes well this coming weekend, paint will be delayed till next year as i will be diving back into some (a fair amount) of fabrication. Because why not go back on a decision i made on like the 3rd page of this thread

[ottawa coupe]

Welp, comittment made, admittedly not the one i was thinking a week ago as it seems i have been ghosted. I WAS gonna get an AAN to put in this. But i sent the message this morning to commit to buying a 4.2 from a C5 S6. 340hp loveliness. I will be achieving my midlife crisis goal of finally owning a v8 lol.

I have been scouring the internet over the past few days regarding how it will work electrically without canbus and and it seems i am down to one last question regarding auto vs manual program in the ecu. I have found someone locally who seems knowledgable about flashing in general, i think (he or i) just need to find the right file. Obviously due to the fab work required to get the engine fitted and solve the radiator issue (the oe MAY fit, depending on endtank size), i will have time to figure that out.

Details need to be worked out but i should have it in a week or so.

In the meantime, i will be pulling all of the sensors off the aah on my stand as most seem to be the same as the aan, so i'll have spares for my s6, although i'd REALLY like to find an iat to complete the set...

[ottawa coupe]

Well, holding breath a bit longer as the seller is going to deliver it to me from toronto. But hotter than hell here and his van needs AC work, i will be patient. Haven't paid yet so no worries.

But the deal has gotten better i believe. The s6 engine had been in a crunch and the timing belt/cam gear took a knock. The internal condition is not 100% known. He happened to be parting a manual swapped d2 s8 as well. So for the same price, he's bringing that instead. 360hp now lol. Bonus, he's providing the clutch/flywheel assembly too. Hopefully only a couple more days....

Does anyone know how much a urs fuel pump can supply? I got into the tank yesterday and cleared out the varnish on the bottom. I have a used oe audi urs pump and a new vdo urs pump. Google suggests 380-400hp. Seems optimistic and not a large margin for the engine i am using. It'd be nice tho as it would slot right in.....

[ottawa coupe]

Ug. Not sure if i am getting this engine or wtf is going on. Things keep "popping up" for the seller, fingers crossed by the end of the week.... if not there is a complete a6 4.2 available for not much more about 90mins from home. Whether it remains available past the weekend tho..... sure, not the big boy 360hp but still a V8 for the right price.

In the meantime, i have started scrubbing misc interior parts and going on a shopping spree on ebay. I must say i kinda hope talk in these parts of joining the EU picks up.... i am stuck for a rear center console in black. The part price is around 20€. Shipping in eu is 10. Shipping here is 170.... so ya, that's not happening.

Not much progress cuz DAMN hot and 700% humidity.... i HOPE to share pics of 4.2l of goodness on my engine stand this weekend....

[ottawa coupe]

Grins in v8....

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It'd be on a stand but the pressure plate bolts are all stripped.....stupid socket heads.....

I am also CAUTIOUSLY optimistic that i can use the s6 rad....