Audi quattro S1 E2

[restricted]

Epic build, just seen this... nicely done

are you using thinner steel? why add weight if it isn't structural and are you adding swaged ribs to the flat sections to increase rigidity?
Just curious

[campbellWS]

Wow amazing progress!

[G60Rallye]

Had some more time on the car this weekend. The rear floor area had to go due to wanting to run the rear diff higher to level out the drive shaft angles. The new floor is 60mm higher than the old one which gives plenty of scope to get the shafts level even when running the car very low.

The old floor chopped out left quite a hole!









Bit of a mess around with a spare diff to see if any of the front floor would need to go but its going to work fine as it is.





So with the old floor out of the way I had a new floor folded up. This is supported on posts from the jig so I know its gone in flat and true.



The new floor in place just tacked in for now:









The vertical section will have a return lip welded on to continue the inner arch line:



The floor goes that far back at the same height so the rear anti roll bar car fit in without any cutting like had to happen on the other car. Delighted with how it has gone in and its removed a lot of rust from the rear end. The next job on the list is to make up a jig for the diff mounting points and extend the cage down to the floor to pick these up.

[G60Rallye]

Door bars turned up last week so they have been notched and fitted. The lowers are bent at 30 degrees and the uppers at 50 to make them lower at the centre making them easier to climb over. Lowered a little over the other car as they are slightly too high in it for my elbow. With those in place it enabled the bars from the hoop to the turrets to go into place. I needed these points as the rear diff pick ups will come down from this location. I have left the bars just pushed into place so they can be lifted out for better access inside.















Very happy with how the cage/ spaceframe is looking. The next job is to remove the rear floor and fit up the new raised section into place.

[OZ2000]

Good progress Hamish!! And fantastic attention to detail as always. Keep it coming.

[Error404]

Yes true there won't be much steel left

[G60Rallye]

I don't think there will be enough metal work left to warrant any blasting or dipping so I was just going to wire wheel it all down and prime it.

[Error404]

Love the door striker brackets, excellent attention to detail as usual Hamish
What are you plans for the shell once the fabrication work is complete? Are you going to get it blasted again or dipped?

[andy10v]

That is interesting.

I had been trying the timer on my mig and its much easier to be consistent, I had only done exhaust stuff with it so far.

[G60Rallye]

Yeah its just mig welded pulsed. M-sport tested pulsed welds and continuous and they were equally as strong.

[andy10v]

The bar inside the sill is really cool.

Quick question, is that a series of mig spot welds on the bars?

[G60Rallye]

Had a couple of days to work on the shell over the weekend and got a bit done. First job was to run a bar down each sill from the main hoop to the A pillar. I decided I wanted one inside the sill down as low as possible for any side protection and also to strengthen up the frame.

So the spot welds were drilled out and the sill folded open. They were in very good condition inside which was heartening considering the shell had spent a long time outside.



The strengthening was then cut out as it was in the way of the bar and is not needed with the space frame. I also welded up the holes for the trim pieces and gave it a dusting of paint to stop any rust from coming through.



Bar notched and in place





Then it was sealed back up again.





The same with the other side which was even cleaner inside.









Next I made up some brackets to hold the door opening onto the main hoop and also act as a piece for the striker pin to attach to. The metal door frame will be replaced with the composite rear wings hence needing something to locate them when the time comes.







Final job of the weekend was to add the dash bar into the cage.





Starting to take shape now.



I had a measure up and have ordered up a pair of doors bars to be bent. They should be here next week which will really tie the A pillars to the main hoop. Next job is to cut the rear floor out so a new raised section can go in and then start dropping bars to it to hang the diff from.

[tartanmotorsport]

Looking great Hamish !!!!

[Greg_S]

making quick progress

[G60Rallye]

I have been back working on this shell for the past couple of days. Another thanks to Joe at Proformance metals www.proformancemetals.co.uk for sorting me out with 25 meters of 40 x 2mm T45 tubing for the rest of the cage. This has meant I have been able to start on all the rest of the tubes in the shell.

To go with this I managed by luck to pick up a 2 door Audi 80 roof and doors which I could not turn down. The roof and doors will go into storage for the future on another shell. It has however allowed me to fit up the doors so I could make sure the scuttle and A pillars went on in the correct position.





Doors in the hole and scuttle/ A pillars welded into position:





A pillar bars run along the top of the door aperture which will be welded to it to get the door shut perfect:



The roof was cut out at the top of the screen to get the A pillar bars up high. I then made up a plate with a swage in to cover up the hole and tie it into the A pillar bar:



Added a roof cross in with the 40mm tubing



Then a couple of bars from the rear turrets to the base of the main hoop. These touch the inner arch tubs which they will be welded into.







The next job is to get the door bars bent up as these set the height of a few other bars coming off the main hoop and A pillars. Then it will be a raised rear floor to get the diff higher and get the cage dropped down to hold it. Coming along nicely now, very much enjoying the build at the moment.