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Project Zombie - 3B back from the dead

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  • Long time since any updates, but plently of graft has been going into the car.

    Got the dash out to fix the heater matrix and whilst it was out I had it flocked. looks really nice and cuts out all the reflection of the dash on the screen.


    Wired in a couple of 30amp relays and associtated cabling for one of James' heated screens. Decided to remove and replace the screen myself with some help from my lad. Nasty job getting the old one out and I needed to treat some rust which had appeared on the screen mating surface. Refitting it was a piece of p*ss, so I'm not sure why some of the fitting places make a mess of the job.


    Pulled out the headlining and pillar trims and covered them in foam backed faux alcantara/microfibre. Another overdue job done and hopefully won't need doing again. I bought a specialist adhesive used for trimmimg coaches, so hopefully the damn roof lining won't end up sagging again. It's now blacker than a black thing inside the cabin. Too dark to see any bits which weren't perfect and too dark to take a decent photo!


    Got the car back on the road and MOT'd and a freeze plug popped. Right nasty job to replace in situ and I'll be changing the remainder next time the motor comes out. I bet there are a few about to go anytime soon due to the age of these cars. It was the plug just above the starter motor.


    Hard launching and 400+ ponies have produced a load of oil puked into the inlet and down onto my Maf, so it's time to sort out the breather system before I f*ck up another Maf. Bought all the parts and received my vent puck from Issam today, so a nice little fabrication job with the TIG and she should be ready ADI at Castle Combe in October.


    Next on the list are top mounts front and rear, already ordered from Albert. New poly front wishbone bushes to be replaced free of charge by Powerflex, due to mine creaking really badly. Rear subframe swap out and replace diff seals. Hopefully then I can enjoy driving her for a while before she needs more TLC...
    Last edited by SteveH; 17 September 2016, 16:42.
    91 Modded 3B
    14 A6 Avant Black Edition

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    • Looking good. What technique are you using to remove the original block breather and what way will you plum the system?

      Sent from my LG-H955 using Tapatalk

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      • Originally posted by diesel des View Post
        Looking good. What technique are you using to remove the original block breather and what way will you plum the system?

        Sent from my LG-H955 using Tapatalk
        Good question!

        I've not removed the block breather before, so I'm hoping I can get a flat head screwdriver or chisel under the outside edge and slowly prise it off by working around the circumference. I could cut it with the grinder if not and butcher it out

        I'm planning on taking the crank vent and cam cover vent into a 10x10x20 baffled tank with a hose back to the inlet. I'll probably add a drain back into the side of the block breather or possibly the fumoto valve. It will really depend on how much oil ends up in tank.
        Last edited by SteveH; 17 September 2016, 16:34.
        91 Modded 3B
        14 A6 Avant Black Edition

        Comment


        • Cracking looking in red Steve. Not read your post for a while but are you running an 2.5 block? Re the oem block breather, where can I get one? I've look but with no joy thus far. Thanks Simon

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          • The OEM is just a press fit into the block. I removed mine as you suggest working around the edge with a cold chisel. Was quite hard work getting it off undamaged, and that was with the block on the stand. You might have to sacrifice it to remove in situ
            They are NLA now I believe
            Panthero Coupé quattro 20vt
            Indigo ABY coupé
            Imola B6 S4 Avant

            Comment


            • Anyone removed the core plug from a tdi block to fit theirs? Seem deal just work around with a screwdriver or did you drill a hole and use that to lever it out?

              Sent from my LG-H955 using Tapatalk

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              • Originally posted by diesel des View Post
                Anyone removed the core plug from a tdi block to fit theirs? Seem deal just work around with a screwdriver or did you drill a hole and use that to lever it out?

                Sent from my LG-H955 using Tapatalk
                I got mine out using a small sharp chisel, or you could weld a nut to the middle and use a slide hammer.
                sigpic
                1991 Audi S2 3B - 2.5 Stroker engine
                1997 A6 2.5TDi quattro avant - C4
                1976 RD250E / 350LC cafe racer

                Comment


                • Originally posted by simon20vq View Post
                  Cracking looking in red Steve. Not read your post for a while but are you running an 2.5 block? Re the oem block breather, where can I get one? I've look but with no joy thus far. Thanks Simon
                  Standard bore and stroke. pulled the motor at 125K and the bores were still within spec. Had them honed and used new rings. It's been fine since and now on 140K. Famous last words No idea about the oem breather, Alex say's they are NLA.
                  91 Modded 3B
                  14 A6 Avant Black Edition

                  Comment


                  • looks like you have been busy Steve, the headlining looks like a top job. Look fwd to seeing it at ADI, will be looking better than my sad looking pearlescent flaker
                    sigpic

                    1992 3b S2 Coupe

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                    • My list of jobs is finally getting shorter!

                      Done:

                      Front topmounts (Thanks Albert)
                      Offset front subframe mounts
                      New bearings in the rear top mounts
                      New front Wishbone poly bushes (Thanks Powerflex for the free replacements)
                      Wishbone bottom ball joints
                      Droplinks
                      Replaced rear subframe with one which had been powder coated (Thanks Colesy & Chef)
                      Solid rear subframe mounts
                      Replaced both rear diff seals and refilled diff with Redline 75/90 (amazing how much difference oil makes in a diff )
                      Catch tank fabricated and in situ
                      Four wheel alignment courtesy of FMC Bristol

                      Car feels better than ever. I really should have done some of this years ago!

                      Next up is a good wash and pics for the Insurance folk to get my agreed value sorted.

                      Last edited by SteveH; 14 October 2016, 09:25.
                      91 Modded 3B
                      14 A6 Avant Black Edition

                      Comment


                      • Looking forward to seeing it Steve
                        How long have you had the Powerflex in? Mine creak pretty badly, been on the car a few years now though.
                        Any pics of your breather setup? Need to sort mine out over the winter
                        Panthero Coupé quattro 20vt
                        Indigo ABY coupé
                        Imola B6 S4 Avant

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                        • Lucky you got all that done, otherwise you'd be really busy over the next 36 hours...
                          Cheers'en, AndyC
                          1994 ABY Coupe - Projekt Alpinweiss

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                          • Originally posted by Rusty View Post
                            Lucky you got all that done, otherwise you'd be really busy over the next 36 hours...
                            LOL...Lesson learn't today. DO NOT loan your prepped car to your son a day before it's due to be at ADI. One broken driveshaft later and we're back on the road for Saturday
                            91 Modded 3B
                            14 A6 Avant Black Edition

                            Comment


                            • Originally posted by Error404 View Post
                              Looking forward to seeing it Steve
                              How long have you had the Powerflex in? Mine creak pretty badly, been on the car a few years now though.
                              Any pics of your breather setup? Need to sort mine out over the winter
                              Had the bushes at least 10 years. They have changed the design a few times and they now have nylon washers on the outside of each bush. If you don't have this version contact them and they will replace FOC. Great service and very quick turnaround. Must say I am impressed by them.

                              Will post a pic of the breather setup. It's a test unit, so not particulary sexy in its appearance
                              Last edited by SteveH; 13 October 2016, 21:40.
                              91 Modded 3B
                              14 A6 Avant Black Edition

                              Comment


                              • Are you tracking it Steve? Be a good test for your breather
                                I'm sure my Powerflex do have the nylon washers. Maybe they just need more grease
                                Panthero Coupé quattro 20vt
                                Indigo ABY coupé
                                Imola B6 S4 Avant

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