My Audi S2 coupè Version 2 - full restore - Red rocket from Norway

[rxl]

wow it takes time to get the sealing material of the s2... you got skills and patience

[kinaputt]

[kinaputt]

[kinaputt]

Drilled out the sport welds from the endplate. Medieblast og weld/zinc primer. Welded back on. Forgot to take a picture when i was finished.





















Drilled out the welds, medieblast og weld/zinc primer.

[kinaputt]

Support for jacking points.

[kinaputt]

More gluing...

[kinaputt]

Done some work...


Welded on the last 2 exhaust hangers.


Made some brackets to reinforce where i jack up the car.


Made from this pipe.


I had to cut out this part in the engine room.
It was rust between the plates.


I made a template with tape.


And made this.


Just need some grinding!

Where can i find/ buy CV boots for the main shaft?
How thick hoses do i need to build fuel system for 700-800hp on e85?
Can 2 fuelpumps be installed in the original tank?
How can i mound a 01e transmission on the 3b subframe, do i only need a spacer on 1 side?

[kinaputt]

This will give you much neater welds on thin metal with about 90% less grinding back to do: http://www.mig-welding.co.uk/thin-metal.htm

The video in right hand column is quite good

If you are burning through often, then you need to turn down your welder, or use thinner wire, or both!

I use 0.6mm wire, the problem is where the rust has made the steel thinner than the new 1mm piece.
I do nealy the same as in the video. I just move to the other side of the piece all the time to reduce heat. Some on the panels twist when they get to hot.

I will try this method. But its easyer to weld a cross when i dident make the new steel piece perfect.

[BATCH]

nice and clean job!

[Bowie69]

This will give you much neater welds on thin metal with about 90% less grinding back to do: http://www.mig-welding.co.uk/thin-metal.htm

The video in right hand column is quite good

If you are burning through often, then you need to turn down your welder, or use thinner wire, or both!

[kinaputt]

Full face mask for a wire brush, goggles are NOT enough unless you like grease/rust coloured tattoos!

Can i ask about your welding BTW? Why are you welding across the joint?

Less heat with spot welds and a lower chance of burning thru. How do you weld?

[AndyP]

Yep - busy busy busy. you must have some advice on what the best brand of grinding disc / flap wheel is, do you find one lasts longer than others?

We use thousands of flap/grinding/slitting discs at work and we've come to the conclusion that Klingspor are the best. Their 1mm slitting discs are really good, I ran out recently and borrowed some Parweld discs off a friend and they were crap compared to the Klingspor ones

[Bowie69]

Full face mask for a wire brush, goggles are NOT enough unless you like grease/rust coloured tattoos!

Can i ask about your welding BTW? Why are you welding across the joint?

[kinaputt]

fair enough!

I've gone off cheaper branded spinning abrasvies/wire wheels after an ebay special wire wheel i was using with my angle grinder became old and started shedding bristles, one of them got stuck in my nose like a spear. Good job eye protection was worn - that would have been bad news for an eyeball.

This kind of tools is very dangerous, if something happends you can get blind, or even worse. I always use eye protection. Some of my discs is sending parts everywhere too, when they get worn out! I also nearly cut my fingers off a couple of times...

[kinaputt]

Powder coated parts!!