Refurbing Audi RS2

[ColonialNomad]

Lol maybe. Just want to get the most out my ownership and I plan on owning for the long term.

[macspring]

Thought experiment: If I decided to forget the value of the vehicle to collectors (but kept the original parts for restoration later) and wanted to upgrade the car to 500bhp for road use, what parts would be needed in addition to those below?

LOL. Careful now, it sounds like you could be getting infected with 'I5 power'itis'

[ColonialNomad]

No update this week apart from the brakes having been finished. The wheel alignment issue isn't due to suspension geometry so I'll be hunting down a wishbone from somewhere to see if that sorts the wheel alignment issue. If it doesn't then clearly something more serious is going on with the chassis.

Thought experiment: If I decided to forget the value of the vehicle to collectors (but kept the original parts for restoration later) and wanted to upgrade the car to 500bhp for road use, what parts would be needed in addition to those below?

Wagner Exhaust manifold
K26/27 ball bearing turbo
040 Bosch injectors
Bosch upgraded fuel pump
Uprated, forged con-rods
Uprated clutch (will keep single plate if possible, dual if necessary)
Uprated 6 caliper brakes (wtih big turbo brakes on the rear)
Milltek stainless exhaust

Would the stock crank, piston heads and transmission be ok?

[RudeCherub]

Really it all depends on the mark up charged by the guy with the printer. I've no idea how much something printed using the usual nylon thread costs.

As best I know when it comes to reproducing parts you use a 3d scanner and then print it.

Like Jay Leno. http://www.popularmechanics.com/cars/a4354/4320759/ old article from 2009

[ColonialNomad]

The web says the CF printer is $5500, "the sample nylon part cost $9 to make, while the useable carbon fiber part is only $19."

So that I suppose in an idea of cost, a little more than double what a nylon printed part.

Still cheaper than Audi Trad prices.

BTW, getting stuff done in China is potentially an option if I can find a 3d printing firm.

[RudeCherub]

The web says the CF printer is $5500, "the sample nylon part cost $9 to make, while the useable carbon fiber part is only $19."

So that I suppose in an idea of cost, a little more than double what a nylon printed part.

http://makezine.com/2015/01/15/3d-printed-carbon-fiber-markforged/

[Error404]

3D printing in any material worth using is still prohibitively expensive.

[ColonialNomad]

http://www.s2forum.com/forum/showthread.php?t=76448

[ColonialNomad]

I believe 3d printing will be as transformational to our everyday lives as the mobile phone.Saltinot and ksimmonds have access to the parts, perhaps others do as well...I'll stick a wanted ad up and see what happens.

[rs2315]

This 3d stuff could gather momentum if enough show interest, and the price is right.

3d printing for old school audis the answer to all our prayers

rs2315.

[RudeCherub]

It has crossed my mind too, there is just recently IIRC last year, a carbon fibre 3d printer, it produces something on a par with aluminium again IIRC, because it isn't 100% CF. I don't know if any one does it in the UK... but a quick google now brings up this page

http://www.3d-alchemy.co.uk/3d-printing-in-carbon.html

[ColonialNomad]

Quick thought today...I was wondering whether someone with access to these NLA underside trim parts might be near another member with access to a 3d scanner...I could investigate 3d printing.

[ColonialNomad]

Dean called Pagid and apparently they don't have any rear disks in stock so I pulled the trigger on Golfboy66GTi's ebay link (thanks again!)

Despite not really working on cars older than 1998, he's found a complete set of RS2 workshop manuals and my car tends to get worked on by him in the evenings because it's something he's really enjoying. Nice to know its in good hands! I've put him onto Pete at Quattro Corner for other bits and pieces.

He tried fixing the rear brake lights this week and it took a lot of time because there is a ground in the car electrics between the light and the engine loom somewhere behind the dash. He'll avoid taking the dash off if he can.

[ColonialNomad]

Rear discs:
http://www.ebay.com/itm/AUDI-80-RS2-...item46142eec62

By pure coincidence, I suggested that very auction to Dean last night. Nowt wrong with Pagids!

After discussions with Aron, it looks like CF items will be outside my budget.

[Golfboy666GTI]

OK update time:

The wishbone bushings have been replaced along with the front disks and pads. Dean is having issues sourcing a set of rear disks however, his usual sources of supply are coming up dry. He's also cleaning and lubricating as he goes.

He has also sourced an ashtray and thanks to a friendly Ebayer and S2 fan, MarkMidge, I have a few replacement Audi 80 trim bits on the way also to Dean. The steering cowl with the hifi control holes is going to be replaced and apparently he's sourced those headlight surrounds (which were apparently an RS2 specific item but the parts numbers match with the 2.6 Avant he's breaking currently)! Have yet to find a ceiling switch though, Mark doesn't have any in black. I also took delivery of a new OEM retractable boot cover yesterday from VRS in Northants.

I'm talking to Carbon Designs on here about CF fuel tank straps but I don't have any information on the dimensions. Can anyone help? Also, does anyone have pictures of the intact intercooler duct and plastic underside panelling? I'm thinking about commissioning in CF also if the cost isn't too high. May be worth a group purchase if others are seeking the same.

I also plugged the Pioneer head into a power supply and I think its going to look pretty awesome. It's a very minimalist design and its possible to select the backlight and display colour in blue to match the rest of the car interior. Have yet to settle on speakers as I'm tempted to take the car into a audio specialist. The real ****** though is the lack of audio/audi specialists even remotely close to where I live in SE London. It's like being stuck in a desert!

Dean is working on the car himself and will be looking at the electrical issues next, I'm missing the car though. Can't wait for it to be sorted enough for a trip I'm planning up to the Peak District in late May/early June.

Rear discs:
http://www.ebay.com/itm/AUDI-80-RS2-...item46142eec62