Project Bus

[Jas11n]

On the heels of Project Sooty (Linky) comes Project Bus.

It wasn't intended to be a project at first, bought as some of you may know for impending family duties, but not to be .
We decided to keep it in the hope it can fulfil it's role in the not to distant future. Besides, we both really like it.

1995 Audi A6 2.5 TDi Avant, 5 speed manual, non quattro with the AAT five cylinder 10v engine (one cam )
And NO!! you can't have/buy/steal or beg the engine for a stroker conversion. OK?

First job, get rid of the really ugly old fashioned grandad style four spoke airbag steering wheel.
In it's place a 1996 S8 three spoke sport airbag wheel. Direct bolt on fit. No modification required other than I removed and replaced the S8 badge on the lower spoke for a sport badge instead. Can you believe that badge is the best part of £35?
Incredibly daft pricing for Audi there.

Bye bye old wheel;



Hello stylish sport wheel. Much better feel and more pleasing to the eye;



Old versus new airbag slip rings. Identical;





Next up was to remove and replace the ambient temp display for a spare. The common problem of the bulb being blown meant you couldn't see the display at night. The one I've removed has had it's bulb replaced and it's now in spare box.
You'll also notice the awful scratched upper cowl? I have sprayed that satin black and it looks like new now. I'll get a pic in due course.
Wondering why the reading was a bit high, I traced the sensor only to find it tie wrapped to a rad hose.
With it repositioned, it's now reading the same as the sensor in the S2 and Sooty.



Next was to try and sort the daft memory losing Pioneer headunit it came with. No luck whatever I tried, it's memory was lost everytime it was turned off (yes, it had a permanent and a separate switched supply) It must just have been knackered.
Off to Helfrauds and I picked up a clearance ex display Kenwood MP3 headunit for £50. Not bad either, it's button illumination is a nice red apart from the scrolling display which is in blue. Can't have everything.



Next up the obligatory clean. Not just a quick wash, but an hour with the hoover, three odd hours with the polisher and a couple withe polish and wax. I even cracked open the Zymol Concours wax (£160 a tub : ) and put it on bare handed. I'm either stupid or a perv in my neighbours eyes.















I also intensely dislike chrome around front grilles. Dunno why, just like some people don't like a kick in the balls, it don't like chrome. I'm so glad the cars window trims aren't chrome either. Badges in chrome, all good.
I used a proper black trim tape to cover it. Still not perfect but got a solution to that as you'll see later.



Next up was to pop an H1 35w HID kit in from HIDS4U. Very well made kits and great customer service from these people. I've used ebay kits from China, and while they are cheap, they don't last long and China is a bit far for brilliant customer service.
The ballast on the nearside was sited on top of the ABS pump, the offside sited on top of the chassis rail to bumper spar.
Now I can see where I'm going on a night, rather than trying to use ESP, guess work and lots of hope. The standard light output is pants.
(excuse the greenish looking pic of the HID light output, it's my camera phone being childish )







Excuse crappy fone camera, they aren't really green :?

[Jas11n]

I bought a tuning box for her too (Thanks Robin "twoqu") .
Slightly different to others I've seen, in that this box has some form of internal MAP sensor that will only pump more fuel in when the turbo is producing a certain amount of pressure and above. Whereas before the power delivery was linear, the torqmaster has given it what I can only describe as being like the S2's, in that it feels like a big turbo car with turbo lag. Ther car accelerates with the same performance as before, but then when the box starts pumping more fuel in, you feel the shove and it's off like a rogered cat. It's a bit mad



A must have was the programmable intermittent wiper relay from a Golf/Passat Had one in the S2 since I bought her in 2004. Nice little upgrade these. (slots into where relay 229 is)



If you scroll further back up and look again at the detail weekend pictures, you'll notice it's comedy trolley wheels (7j x 15" ET47 on 205/60/15 tyres) Why on earth they had 15" rims is beyond me. Makes the car look all sucked in like a bulldog chewing a wasp.
You'll also note the comedy ride height. I'm sure I'd get away with riding around an American monster truck show without being laughed at.
So, new wheels called for. They initially where going to be 19", but took it under advisement that they would maybe cause rubbing in places.
So after using this nice little wheel offset calculator >>> Linky and a tyre size calculator >>> Linky I decided on 8j x 18" ET35 with 225/40/18 tyres. This would move the wheel out of the arch to get rid of the sucked in look, while not rubbing on any suspension or wheel arch liners.
Also wanted B5 RS4 9 spokes, but spotted something along the same lines but just that little bit different.
Replicas of the 18" wheels fitted to the latest Golf R32 and all Passat R36's. Same sort of style, but with 10 spokes. Bought from Wheelbase in Oldham for £485 with tyres delivered to my door.









Back to the front grille. It bugged me that I could see two joins in the trim tape. Have a couple of times caught the trim tape while washing it too. Spraying isn't an option, and neither is the OEM black rimmed S6 Plus intem. Not at £200 it bloody isn't.
Solution? A black rimmed FK Automotive badgeless grille from germany. I have a couple of old 80 grilles and I'll remove the four rings badge including it's raised seat, and retrofit that neatly to the new grille. Hopefully when done, it'll look OEM. Lots of patience with the dremel I think.





The wheels came without centre cap badges as wheelbase were out of them. But they arrive a few days later in the post and look great. They are made out of aluminium and aren't just a sticker.



After browsing fleabay, I spotted a pair of headlamps with the incorporated fog light. Mine are blanked off, but thought a quick bid wouldn't go amiss. Bargain fleabay auction won for 99p each.
I'll use both sets to make a perfect set in due course, then wire them up through a 30amp relay and OEM dash switch.

While hoovering the cars seats (which I might add are sports seats. Absolutely lovely seats too, soo comfortable and have extendible thigh supports), I noticed a hard fitting behind the cloth of the passenger seat upper inner side bolster. Hmmm? a quick prod around through the cloth with a thin sharp tool, I could feel a thread in the middle. Bingo!! it's the mount for the armrest optionally fitted the non UK models, never available on UK 100/C4 A6's (though dunno why)
Makes sense I suppose, why make two versions of the seats??, our passenger seat is a LHD drivers seat. So a searching daily through ebay germany eventually paid off. I'd seen a couple, but both were in leather and both had stupid start prices (£100+) The seller I found had a cheap start price, but his listing stated shipping only within Germany. Booo, why do they do this? A bit of google translation tool usage saw a message to the chap who turned out to be great. No problem shipping to GB and he even changed his auction and added a BIN price. €36 sees it on it's way to the UK all in. Bargain.





Next up, that awful ride height. I initially settled on a Spax sport kit, but it seems they don't now do it. So I've just taken delivery of a 40/40 set of Weitec springs. No shocks as of yet until I find something suitable. I'll probably end it down the Koni route.

[Jas11n]

The front bumper looks all wrong. Like a big mother version of the 80 TDi speed boat bumper. Can't be having that. It needs something low down low to beef it up a bit.
My mate James was the inspiration of the idea to buy and fit a Seat Leon Cupra R front splitter and see what it looks like after he last year fitted one to his 04 A6 Avant TDi. If it doesn't suit, I'll flog on fleabay.
Here's what I'm rambling on about





The engine got a spruce up for Stanford Hall show the other weekend.
Came up nice.



Ok, so front Seat splitter obtained and fitted.
Bit of a challenge this one. The underside of the speed boats hull in a right pain in the butt to site the splitter well. Bit cutting here, bit cutting there, tweak here, redrill and self tap here there and everywhere. Eventually got it looking how I wanted.
Looks cool I think, I like it :woot:











Also fitted the FK grille for now until I obtain another standard A6 one to chop about (I don't like chopping up stuff I may need later, hence original will go in the loft) The 80 grilles I had were a no go. The slats obviously were way out to retrofit in.
Doesn't look as bad as I thought it would without the rings, though with the rings looks better. Just not totally duff if you catch me.

The armrest turned up from Germany.
The hex---ish fittting that keeps the armrests fixing point securerd in place. The bolt is through the centre and secures it to the seat frame.



You can see the fittings behind the seat cloth after I've cut it open (scary believe me )
The hex slots into the socket on the seat frame, the bolt then secures it.





Slot the armrest hex thing into the socket, tighten the bolt and you're done.
Simples.
Ok, the cloth doesn't match "exactly", but it's not kicking the arsé off is it? More than I could have hoped for from a picture on german ebay bought blind in a sense..
The top opens to reveal the inner, the whole armrest clicks up a notch at a time to about 45°, then all the way up out of the way.

One happy bunny.

[Jas11n]

She's back from being lowered.
40mm all round. Decided after hunting for an age for suitable shocks that didn't cost the deficit of a small country, to retain the standard ones and cut the bump stops down 20mm.
She rides exactly the same as before. Nice and smotth. Don't forget, this ain't no sports car like the S2.



Original;



With new wheels;



With the 40mm drop all round;





Now I'm thinking this;



by purchasing a set of these from germany;







They'll need converting to a RHD beam pattern, been there done that on another set I once had for sooty project. Looks miles easier as access is way better.
Best thing is, they are in the OEM style, no angel eyes

Those, along with piano black B and C pillar trims and side/rear window tints.

Hmmm, do I? or don't I.
I'll sleep on it and decide tomorrow.

[andyg plym]

excellent work jason, you are like an online haynes manual !!

didnt my old temp display end up in your sooty?

[Jas11n]

excellent work jason, you are like an online haynes manual !!

didnt my old temp display end up in your sooty?

I think it did yes Andy

[andyg plym]

jas silly question.....if i sent you my dash switches (heate screen,couple others) could you solder in some new bulbs? ive gone mad trying to source some new switches etc but i have the large long back style type, as mine is an early s2 aby.
i could do it myself but to be honest you would do a MUCH better job

obviously id make it worth your while

[GT500]

Great car! Love the up grades!

My old man has an AEL saloon, best thing I've done to it was getting rid of the cat. o and a pair of chips from James!

I am stripping an Avant to use its engine in my LT35. If you need any bits let me know..

[Jas11n]

jas silly question.....if i sent you my dash switches (heate screen,couple others) could you solder in some new bulbs? ive gone mad trying to source some new switches etc but i have the large long back style type, as mine is an early s2 aby.
i could do it myself but to be honest you would do a MUCH better job

obviously id make it worth your while

No problem. I'll PM you my address and you can send em up.
Don't want nothing for it, got loads of LED's and bulbs

Great car! Love the up grades!

My old man has an AEL saloon, best thing I've done to it was getting rid of the cat. o and a pair of chips from James!

I am stripping an Avant to use its engine in my LT35. If you need any bits let me know..

They're great aren't they. Bags of torgue, surprisingly good handling for a big spongy old bus and just eat the miles, especially with the cruise set. Just get comfy and waft along at illegal speeds with ease
I'm panning on taking her up to AAS exhausts in Newcastle and getting a custom SS whilst removing the cat.

You'll notice the tow bar fitted. I'll never have need of it, so will remove it. Thing is, whoever fitted it cut the lower black trim part.
Looking in the FA the other day, seems that trim can be replaced separate from the bumper. Held on with small plastic split rivets.
I'll gladly pay you for that Rob if you've still got it. Saves sourcing a complete bumper and possibly getting it sprayed.

[A80Avant]

Nice one Jase, i guess the rs4 is out of the question then....

Been to Stuart in AAS, i get the impression he is fed up with me building downpipes all the time for the rs2!!! haha

Make sure you call to book in, as he has roughly about 4-6 weeks waiting time...

[Jas11n]

Nice one Jase, i guess the rs4 is out of the question then....

Been to Stuart in AAS, i get the impression he is fed up with me building downpipes all the time for the rs2!!! haha

Make sure you call to book in, as he has roughly about 4-6 weeks waiting time...

RS4 was nearly purchased. Found the one I wanted and had the funds ready to go in the bank.
Then Allie fell pregnant and everything changed. We bought this as a family car. It's huge in the back, loads of room for all those kiddie parts that come with family life.
Drop the rear seats down and I swear two could happily sleep in the back full stretch.

Then Allie lost the little un and our world fell apart for a while.
But we both love it, so we are keeping it in the hope it'll fulfill it original role soon

[A80Avant]

it happens jase, you can try again! its quite common.the bus may still have its use

[Acidburn]

Great car! Love the up grades!

My old man has an AEL saloon, best thing I've done to it was getting rid of the cat. o and a pair of chips from James!

I am stripping an Avant to use its engine in my LT35. If you need any bits let me know..

Agree with james's chips his car goes very well and doesn't sound too bad when on the limit.

Looking good jas, saw this on audifans when I last came on. look forward to seeing some more updates/pictures. Same seats that I put in my tdi avant rep (but quattro script one's, they are brilliant)

[GT500]

The one I have had a tow bar fitted with cut out..

I am fitting the bar to my dads, I'll take his off and you should be able to have that one!

[Jas11n]

The one I have had a tow bar fitted with cut out..

I am fitting the bar to my dads, I'll take his off and you should be able to have that one!

Cheers Rob. Just give me a shout when you are ready



Over to my dads today to give the soot monster a clean prior to going to it's temp carer next weekend. Be rude not to get some pics in the sun.