Audi quattro S1 E2

[Error404]

If there is a next time, I'll try that then. Must say I spent many many hours wire brushing it off anyway so anything can improve on that technique

[G60Rallye]

I used a chisel yeah a little bit of heat gun but you dont need much. Just got to go for it and be prepared to spend quite a good amount of time on it!

I suspect it was a very solid shell when it was taken off the road. The rust will have come from sitting as a stripped shell for 7 years outside. Back of the floor sections must have had water in them and the A pillar is the usual sunroof drain chucking loads of water into it.

[Error404]

Great progress Hamish. you have made a tidy job of removing the underseal, I too went for the wire brsuh on the angle grinder method, which amde a mess and was a PITA to get into the corners. Did you melt it off with a heat gun and scrpae it off with the chisel?

A-pillar looks like a bit of work but the roof section I guess will help take care of a fair chunk of it. Odd how the few sections are rusted through but most of it is solid as a rock. Rust is the devil.

Looking forward to seeing the chop mate

[Greg_S]

Thats quite a project you've got on your hands. Gonna be quite of welding and fab work to keep you busy over the winter

[G60Rallye]

Have been getting on with cleaning the shell up so the grinding and welding can begin!

All the underseal off the floor pan. Weighed it because I am sad and there was 10kg









Its already made its own cut for shortening!



2 full bags of underseal!



Next I moved onto the inside and managed to get another 10kg from the sound deadening. Ontop of that I started removing all the brackets and metal work. Lots more to get chopped out but want it on the jig first.









Another 2 full bags!



Got a nasty bit of rust to sort on the A pillars. Apart from that the shell is solid. The floor area where its rusty will get chopped out when its shortened.





I have managed to get myself a roof from an Audi 90. 4 door obviously but I am going to use some composite B pillars to sort that. I also got the doors off the 90 to make sure the new roof goes on right.



Chopped the roof right down will use the new roof to repair the tops of the current A pillars.



Next job is to get the chassis jig made up so it can all be held square for being chopped to bits. Should be getting on with that this week.

[SteveH]

Another lovely project underway! Great garage, wish I had space above the floor to hide a project from the Mrs

[DJones]

It's going to be a nice project given your quality standards..

Just wish I had the time to do another project...

[G60Rallye]

I am thinking it will take a couple of years to get the shell sorted. Perhaps a bit less but I am in no rush.

I have drawn up the jig which I am going to go and order the steel for this week. Having sliding bits is a bit complicated there is a far simpler way around it.

No plans to go for an alloy engine. I am happy with how the current engine has been holding up.

[AngryTaco]

This should turn into something awesome. Can't wait to see what happens. Are you going to try and procure a real all-aluminum 2.1L Turbo?

[ralleyquattro]

Subbed.

[martinws]

Great to see another thread that will overtake everyone on views within a few days. I would be interested to see the setup you use to cut and shut. I've thought of a few 'subframe mount' mounted jigs that slide the two halfs to get everything square.

[Rocco]

OMG, what amount of work

when do you expect to finish it?

[G60Rallye]

A chisel and some effort! I have used a wire wheel before but it just makes a terrible mess and takes all the paint off.

[Qwerty]

Another incredible project

Can't wait to see the progress on this one.

What tool are you using to remove the underseal? I used a wire wheel on the grinder for my 205gti, but it was very messy.

[Nuvo]

Subscribed with much interest.

I defy anyone not to be impressed by the fine work you do. Loving the trap door.