Audi quattro S1 E2

[G60Rallye]

Cracked on with the shell work today cut the same out of the opposite side first thing:



Cut the last bits holding the 2 halves together:





Sat happily on its legs:



Brought back in and welded under the windows to hold the door shuts. Have left the floor for now until the main hoop is in place then I know where I want the floor to go. Plan is to have the main hoop intersecting the 2 halves of the sill.









Screwed the B pillars in place to get an idea of where they are going to go:





Got over 25kg of metal cut out during shortening:



Finally chopped the dash panel out and opened up the A pillars to get a look at the damage!



How it stands tonight got a good bit more space to walk around it now with the 320mm cut out!



Next job is to get the roof on and sort the rust in the A pillars. Very happy with how its progressing!

[Kieron20V]

Awesome stuff.


I would sell all 3 of my livers for that garage.

[G60Rallye]

Set about the car today. The roof was first in the firing line!





Off she came!



Behold the open top quattro!









Next I set about the B pillar and floor area ready to get it shortened. Bear in mind the idea with this shell is to be as light as possible and it will be more of a spaceframe with a bit of shell left to keep the water out!

Outer arch chopped out:



Bit of strengthening removed:



B pillar was 3 skins:





They got the chop as I only wanted the door shut left it will be tied into the main hoop of the cage.



Rear chassis member cut out as it wont be needed.





Quite a pile of bits cut out!



New B pillars look like they will work nicely:



Same treatment for the other side tomorrow and it will be brought in on the jig and tacked back together.

[martinws]

Looking really good. Would be good to set up a time lapse of the chopping.

[Error404]

Great progress mate - enjoy your weekend of butchery

[G60Rallye]

Cracked on with some more work today. Got the front chassis legs tied into the jig. Very happy that it all measures up straight as often they have had a little bump! Ignore the lower panel being damaged it was folded up when i used a jack under it.



That meant the front end could be chopped out giving a lot more space to work around it.



Finally I tied the A and B pillars together to keep them true when the roof comes off.





So over the weekend the shell can be shortened and the roof can come off! Hopefully having the shell tied down will mean nothing moves too far!

[europeanme]

I hope you've got some strong beams under that floor!!

that was the first thing I thought of when that great girder was placed on the floor panel....

Hamish, that has got to be one of the coolest garage "solutions" I have seen for a very long time!....

[martinws]

Looking really good hamish. That jig seems really simple compared to the idea I had in my head. I'm watching this with great interest.

[G60Rallye]

Been working on the jig these past couple of days and managed to get the car mounted up on the jig. Big thanks to Jay Birchenall for supplying technical drawings for the shell which helped greatly making the posts.



















Slowly getting my eye back in with the welder.



I have got some 100 x 50mm box to bolt across the jig to increase its width to go up into the turrets and front chassis. Will get the front chassis tied into the jig and then get it chopped and shortened over the weekend. Its moving along very nicely I think!

[G60Rallye]

The floor strength is massive I have no worries with that.

[AndyP]

I hope you've got some strong beams under that floor!!

[G60Rallye]

I will of course take lots of pictures and put them up at the time. It perhaps might not be an ideal way of doing it if your running without a cage as the cage in this shell will be integral.

I have had a nice delivery from Andy Krinks of some carbon/ kevlar B pillars which is the first part of the puzzle for the body work. Roof is next on the list then the cage can begin!





Next part of the puzzle which has held things up has been the chassis jig. I had worked out I wanted 80mm hole spacings on the jig as that means going forwards 4 holes gives the magic 320mm to shorten it. That meant using an I beam with at least a 100mm top plate. I ended up with 178 x 102 beam, 19kg per meter which was the lightest with a 102 top plate. Went with 4 meter lengths so its long enough to bolt to all the vital points. The width is set by the subframe mounting points. 196 holes drilled in total down its length so anything can be added including cross beams to increase the width for getting into the strut tops etc.







So once that was done it was time to get it up on the loft with the shell. Big thanks to my mate Jamie who came down to help out as I couldn't have done it by myself!

First job was to get the shell over on its side out of the way to drop the floor down.



Loaded the jig into the back of the van and drove it around to the garage as its bloody heavy!



Jig pushed up the ramp with 6 sheets of 3/4" ply to go down on the floor. Wanting to spread the weight of the jig/ shell and seal up the floor so no debris gets onto the car below.







Boards down to seal it up for what could be quite some time!



Tomorrows task is to make the pillars to bolt to the subframe mounts and then the cutting and shortening can begin!

[Billman]

Please make good pictures of how are you going to manage the roof and B-pillars from the 4-door sedan.

[martinws]

Looking good so far. I hate underseal and sound deadening. Im really looking forward to seeing the car on a jig getting chopped. I sometimes rather look at the build pics than the finished car.

[Sleeper_Avant]

when i sold my 1.9 5S CD the guy was adiment the screen pillars were the same as a SQ and it was just gonna get chopped up

is the rake the same?