My AAN 2.2 20v Turbo B5 A4 Avant build

[Sleeper_Avant]

did a bit more on the gearbox mounts today.

both side pieces spaced and fitted.

lower cross section "fits" but i hate it so will modify it when the gearbox is out again.

made the final piece in the puzzle for the mounts.........

this is my take on the B5 fanatics "DTS" or drive train stabilizer they all rave about,

i.e lower suspension strut brace i will be also using to mount my gearbox onto the chassis






then when its done i want rid of it, NEED one of these in my life, and for £10k id be an idiot not to buy one!! i love this car to bits so so much i talked to the guy and he said he would accept 10k bye bye audi lol

[Sleeper_Avant]

on second thaughts i couldnt sell the A4, its worth **** all lol

wonder if it was an option for a towbar on the DB7? lol

[Greg_S]

Like the brace, been planning on making one of these once I get some time off DIY at home

[Sleeper_Avant]

dead easy mate, i wouldnt use 42mm CDS though, bit overkill but it fits in the B5 bolt cups well and it is the gearbox mount for RWD only after all on mine

Sean.

[Sleeper_Avant]

"finished" mockup of Drive Train Stabilizer / gearbox mount





engine and box back out for the last time this week!
will weld centre diff up, finish 100% my garbox mounts, tidy them up and paint them etc. (will do some gussets as it will get a lot of abuse)

then clean the AAN block, might freshen it up with rings and shells........ undecided yet but i will paint it either way.

then refit for the last time before it gets driven

home straight now...... i can see that dim light betting brighter

also just ordered a pair of seat mounts for my race seat,


oh, also picked up my ally hubs.... damn these are light!!

i will gusset and finish my remaining bits of "crossmember" / suspension lower mount pickups

then its manifold time

[spink]

wonder if it was an option for a towbar on the DB7? lol

I would say so Sean

http://www.youtube.com/watch?v=Co-NRcJ_NmI

[Sleeper_Avant]

oh wow!
what a tit he looks lol!!

[Sleeper_Avant]

did a bit more tonight

yanked the engine/box out for the LAST time before its first journey in RWD mode

for those of us that havent welded the centre diff this is how I did it:

now im not going into "help the fuktards" mode, we are all mechanically savvy to get to this point or we wouldnt be doing it......... right?!

this can be done with the gearbox "in the chassis/shell/car"

with the propshaft removed,
drain the oil
take off the Torsen centre diff housing.... various T50 bolts (hammer them home, propper whacks not gaylord taps!)


when it is on the work bench, (with GOOD circlip pliers)
get a slim punch, tap the circlip round left to right in the eyelet holes untill its free and moving.
using the circlip pliers and 2 small screwdrivers fish it out of the crevice it lives in,
(useing suitable items, clean the area free from swarf and crud as the tail housing will be open to the elements and dirt now.........)
using a suitable bolt (M8x1.25) fish out the rubber/plastic "bung"
(take note of how much silver goo is in there, any major chunks? if so start again with a fresh g/box!)

ALSO NOTE............
dont wind the bolt in too far as you will breach the seal and you will have to replace it, dont be useless lol

then when the bung it oot, you need to knock the torsen centre diff out of its home.
(i used a 45degree angled pry bar but there are various methods. it pops oot very easy and wiggles out once drifted out)

i then took some brake cleaner and soaked the torsen untill oil free and let the solvent dissipate.........

now we can begin welding........

crank the power and wire speed right up on your MIG and you want to do this to all 3 areas on the torsen.





CAREFULL as the torsen will be VERY HOT!!!

after you have done this (with no birds nest wire or pidgeon s h 1 t blobs on the torsen as it will break off and float round your gearbox!)

leave it to cool down as unless your welder is as cheap and useless as you are then i have no sympathy lol

i took the oportunity to use fine grit paper and clean the mating faces of gearbox/tail housing

then brake cleaner`d both inner surfaces free from crap and dust,

then using a TINY line of (i used genuine VAG) sealant on the mating faces
too much and it will break off inside the g/box and cause unwanted wear and drift round the internals generally being a **** lol!



now put the torsen housing back onto the gearbox, locating the dowels and tap it home.

it will give spring resistance about 10mm from face clearance, this is due to the spring inside the 2 housings.
at this point you want to clean the threads of your bolts (PROPPERLY!)
then use a dab of Loctite and screw the bolts in hand tight, then Torque them up via Audi specific values..............

once done you should have no more than this amount of sealant visable




if you have more than this you are a **** lol
and you also put too much on the mating faces, never mind

stand back and admire your bodging-ness

refit g/box and pull away using the rev limmiter, and smile

hope this helps a few other people out.

[Sleeper_Avant]

i also cleaned the AAN block with several various wire brushes, and a drill,
masked off all the important dirty holes,
covered myself in rust/paint but its ready for a lick of **secret** paint!

yaaaaaay, cant wait

will also paint the engine bay in another **secret** colour since its all out,

i think i need to cross-brace the chassis mounted engine brackets, not happy with the flex angles im getting

no pics, dont need them yet

[djh]

nice update

[sidrick]

Haha, top update

[Sleeper_Avant]

oh, and the project has been renamed...............

Project QuattNo

see what i did there? lol

Quattro badges will be kept but with a big red X across them!!

[Sleeper_Avant]

right, sick of fabricating and metal work so tonight i wanted a change.

thaught id wire in the old A4 clocks......................

so i did that, all working, lights/wipers all good!!

then it reminded me of the disco i used to drive with flashing:
ABS/ESP lights
IMMOB light
handbrake
etc

i know, i will disable the LED`s!

totally ****ed the clocks now PMSL, ive just thrown them in the bin, what a tool lol

anyway, i decided to stick with my plan of a custom dash pod, so a blessing in disguise really!

decided to mock up my dash binnacle and switch pannels (after i decided to keep the dash top, add to the sleeper look and all that wink wink!

anyway pics!

keeping things to my OCD needs
pressures on the right and temps on the left






then i got bored and came home for a beer

anyone got any thaughts on this layout?

getting there, slowly but surely!

[Sleeper_Avant]

if you look in the background of the last picture you can see the clocks that i ****ed then threw in the footwell in a huff lol

[andy10v]

No speedo at all?