20V CQ Tidy Up

[AndyP]

No, I drilled about half way down, then cross drilled it through to let the grease out.

[Error404]

Cheers andy,

I might have a go before I rebuild these

[Error404]

So I ended up going for the "AndyP grease nipple mod". It turned out to be an expensive mod as I had to buy a pillar drill in order to do the job properly
Still it was a good excuse as I've been meaning to get one for ages. This popped up close to home so I figured why not?

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I also upgraded the handbrake lever seals to R3 Viton. The standard ones are boggo nitrile rubber and not up to high temperatures IMHO.
These are about £5 each, for reference the size is 16 x 24 x 7. The R3 seal has an outer lip to protect the oil seal from dust & debris.

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The "AndyP mod" - drilled & tapped the lever for a grease nipple:

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Made a little tool to compress the spring cage to rebuild the rear caliper, worked nicely:

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All back together:

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B5 RS4 hubs & rear carriers:

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Finally got hold of a left hand RS2 brake duct to complete the pair, been looking for one for years then Audi Tradition had some so I pounced before they disappeared.

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I also built up the front calipers. These are Movit, same the 429/430 996TT / GT3 4 pots. I picked these up on the cheap as they were stripped and the guy had lost the pistons. So all new seals, boots, pistons, bleed nipples and crossover pipes. That was expensive, but good as new now though and they probably owe me about the same an average used set


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[AndyP]

Nice work You'll wonder how you did without that drill soon!

[newsh]

Posh! We have one of those drills in the workshop, couldn't live without it.

[Error404]

Yeah I'm well pleased with it, also bought a machine vice, some centre drills and a centre finder. Made it too easy

[AndyP]

Which centre finder did you get?

[Error404]

Just the basic V type worked perfectly:



I've got a wobbler too, but need to get a compound table to use that with the drill

[andy10v]

Nice new toy! Are you going to get a compound table or a cross vice?

That lot should see stopping pretty well covered then!

If the front calipers have cost the same as a a used set then I would say you have come out ahead with all the new bits fitted.

[Error404]

Yeah I'd like a compound table, decent ones cost though. Cross vice would be a good compromise I guess

[Error404]

Spent a day on the coupe today


A few jobs are underway.

First off, gearbox mounts. I'd been getting the odd bang from the big 0A3 gearbox hitting the tunnel on high rpm 1st to 2nd gear change. The gearbox mounts were pretty old, but I decided to try something new. I need to lock down the transmission but don't want the harshness of solid mounts. I'd heard rumours about using old aircooled 911 engine mounts as uprated gearbox mounts so thought I'd give it a try so I picked a pair up:

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They have a similar shame and the same bolt hole spacing is the same. The main through-bolt is M12 as opposed to M10 of the OEM mounts.
They are a bit taller than the OEM mounts and I don't have room for this difference, so I got some spacers laser cut from 304 stainless:

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The mounts use special curved washers each side to retain them, only a couple of quid each from Porsche. The whole assembly will be pretty stiff with next to zero movement.
Hopefully it's not too harsh. If they work well I will do the same with the rear diff mounts.

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Next up I started fitting the Wagner reverse intake and intercooler kit. Since I did a dyno run pretty recently me and Danny of DNA fame were interested to see what difference the kit made to a "standard car". So I'm fitting all of these bits and going to run the car again, on the same dyno to get a back-to-back


Intake manifold trial fitted:

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Bumper off and intercooler trial fitted:


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Bumper back on to check clearance:

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Bit of trimming to do on the bumper - it will fit but I don't like stuff to be rubbing. 10mm around the edges will do it

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Made some little braces for the intercooler:

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Just waiting on a few parts to arrive over the next couple of days.
More to follow tomorow on my throttle cable solution

[Fat Audi 80]

That was my next question, are you going to have to cut the bonnet???

[Error404]

Hey Steve Yeah I will have to cut the insulation for clearance on the throttle cam.
I did look at dropping the engine but that would require spacing the subframe down too and throwing the roll centre way out.

[newsh]

Hey Steve Yeah I will have to cut the insulation for clearance on the throttle cam.
I did look at dropping the engine but that would require spacing the subframe down too and throwing the roll centre way out.

Its the Plastic piece that holds the insulation that needs to be cut, and the rad trim. I was looking at Doug's car at ADI, it has a cool mod to the IM to rotate the TB, was thinking about doing something similar to mine, I dont like the way the throttle cable arrives at the throttle cam at a weird angle.. I'll see if I can find the pic.

[newsh]

Here we go