My silver RS2 Project

[Tractor Dave]

Thanks Rob. I did search high and low for those but somehow missed that.

[Tractor Dave]

Kit kindly sent me a pic of his engine bay so I was able to correctly route the unusual rs2 specific pipe in the correct way. I've got most of the coolant pipes re fitted now.

I got the injector rail fitted. As I suspected, fuel pipes will need some work to get them to fit.




I also re fitted the gear linkage. I can get all gears except reverse but have no clutch as yet. It might need a tweak. The gearbox end joints got plenty of rubber grease.



Happy new year everyone. I hope you are enjoying the thread. Smiley face.


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[Ian Simmonds]

Happy new year too Dave. Look forward to popping in, in 2025.

[newsh]

HNY Dave, great progress!
Oil cooler duct will be in the post tomorrow.

[Tractor Dave]

I found just enough 8 mm pipe left over to make up a couple of tails.


And the gasket arrived and appears to be a good fit.

Thanks for the link Rob.


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[Fat Audi 80]

Somehow I have only just stumbled across your thread Dave!

I have just spent a very enjoyable 45 minutes catching up on your progress.

Thanks for documenting your work and keep the updates coming!

Cheers

Steve

[Tractor Dave]

Welcome to the party Steve

[newsh]

I found just enough 8 mm pipe left over to make up a couple of tails.


And the gasket arrived and appears to be a good fit.

Thanks for the link Rob.


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Tidy!

[newsh]

HNY Dave, great progress!
Oil cooler duct will be in the post tomorrow.

Er, I forgot sorry, hopefully will remember tomorrow!

[Tractor Dave]

Newsh very kindly donated his spare oil cooler shroud to the project. What a top bloke he is. Always willing to help.




So I set about it with a wire brush. There are a few holes but nothing I can't sort.
Then it got a good soak overnight in home made de rust solution.


And then it set about repairing the holes. The metal is exceptionally thin and very difficult to weld without making holes. I decided to wrap the outer holes with a new layer rather than try and cut out and patch.






I set the mig almost to minimum. Only made one new hole. A copper piece behind the hole and I was able to weld it back up.


A quick test fit. We are good.


Then over to the paint booth. Two coats of zinc rich primer then two coats of Novol protect epoxy.


Kit kindly sent me a pic of his engine bay so I was able to get the bulkhead connectors in the right order.



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[newsh]

Nice one Dave

[Tractor Dave]

Before I fitted my oil cooler I wanted to sort my right engine mount. It suddenly started to leak a red fluid.


I think I probably strained it when putting the engine in. Anyway, Sal on the forum came up with a good second hand one. OE are no longer available and I doubt a Febi one would last very long.
Then onto the oil cooler.
The welding of the tab's isn't so good. I can't re use the original speed nuts.


The tabs don't stick out far enough.
So I raided my stainless steel store.

You can just get inside to use a nut.



Then I was able to get fitting. The big tractor spanner's are handy for the oil pipe fittings.





We are looking good so far.

I also re fitted my throttle body.
It was a bit grubby inside.

So got a good clean.



I used a light spray of Holymar on the new gasket.

Next on the jobs list is to sort out all the vac pipes.


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[jbrentd]

Nice work Dave, as always! Nice work on the shroud. It would have looked like swiss cheese if I tried to weld on it.

[Tractor Dave]

Thank you. My welding has improved slowly over the years. I still need to master the tig.

I didn't get much done today. It was freezing in the garage.

Just routed the wires to the starter and oil temp sensor and put some silicone hose over a section of the oil pipe that was rubbing previously.




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[Tractor Dave]

It's still freezing.
Front end coming together




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