Audi quattro S1 E2

[G60Rallye]

Time for an update on this build. I ordered up the roll cage tubing at the start of January. Big thanks to Joe at Proformance metals www.proformancemetals.co.uk for sorting me a great price. The tubing is proper T45 grade not the fake stuff that is doing the rounds. It is 1.750" x 12swg (44.45 x 2.6mm). With the tubing here I needed some templates so the tube could be bent to shape. I decided to use wood for the main hoop template, got it nice and tight to the B pillars so it can support them.









So that was delivered to Protection and performance with a jig for the A pillars. It took 4 weeks to get bent as they were so busy hence not doing much with the car lately. I had the pieces bent with 250mm added to the legs so they come through the floor. These will be used as jacking points and to weld the sill tubes to.



So this weekend it was time to get the cage into place.





Nice and tight to the A pillars:













So that is where its up to at the moment. Next job are the rear stays from the hoop onto the new turrets. This will finally put some strength back into the shell and the cage can develop from there.

I bought a pair of top mounts for the rear so I can get the tubing in the right place as I want it to sit on top slightly. They are actually designed for a mk2 escort and have huge 20mm aurora bearings in them. I am going to have these bolted to the top of the turrets like modern wrc cars for easy of adjustability.







Hopefully should get cracked on with the build at a faster pace now!

[andy10v]

Nice.

That is a really neat idea using wood for a template, so simple.

[retropower]

lovely work as usual!

Ditto re. the wood, might nick that idea! I have always used plastic waste pipe and solvent weld fittings to mock up but the plastic is a bit wobbly on the really precise bends, a degree out is as good as being in a different car! I think wood would be a tad stiffer, and just as cheap.

cheers

Nat

[G60Rallye]

I have finally had some time to get stuck into this build again. I have the core of the cage notched and tacked in place.















Tubes are notched so they sit up on the lip of the suspension turret to help with strength. Spaced the bars out to spread the load so they dont tip under bit load.



Very happy with how the cage has gone inside whats left of the shell. Its very tight to the A and B pillars and the main hoop is hidden by the B pillar from the side profile. Almost ready to order up the small diameter tube now!

[andy10v]

The cage is really tucked in close!

How do you notch the tube?

[Bowie69]

Grinder works well

[my2000apb]

very nice progress

[G60Rallye]

All hand notched with a grinder. Takes a lot of time but the sander type notchers are big money and the hole saw ones are a joke.

[andy10v]

Cool, thanks for the info.

[G60Rallye]

Done a bit more this week and today. I decided to put a bar in at the base of the main hoop. This obviously adds massive side impact strength and ties the 2 floor pans together at the same time. I am also going to use it to pick up for the rear seat mounting.

Firstly the floor got cut back to sink the bar into:



Took a bad picture of a notch all done with a grinder:



Then welded the bar in place and cut some floor sections:







Underside of the floor/ tube tacked together. This will be welded and smoothed off. The main hoop will be cut back but left slightly low as a jacking point.



Its coming along nicely now. Next big job is to weld the scuttle/ A pillars into position then the A pillar bars can be welded in to complete the core of the cage.

[andy10v]

I take it the the prop is going above that bar through a too be made hole in the new sheetmetal? That should stiffen things up a lot compared to standard!

What about the exhaust?

[Clive A]

Looking great Hamish.

[Ian Simmonds]

I take it the the prop is going above that bar through a too be made hole in the new sheetmetal? That should stiffen things up a lot compared to standard!

What about the exhaust?

The prop will be below the bar, that bar is the same floorpan line as a standard car, AFAI can see...

[G60Rallye]

Propshaft will be well above the bar even as standard. I will be running the engine, gearbox and rear diff raised 2" in this car to get the shaft angles back level as it will be run very low like the other car. There will be a new larger tunnel going in at some point in the future and a raised rear floor over the rear diff.

[martinws]

I take it the the prop is going above that bar through a too be made hole in the new sheetmetal?

Probably FWD to save weight!

Looking good Hamish. Really like the idea of the jack points and bar between sides is that bar a standard thing in modern wrc cars?