And finally, my RS2.

[cardcrash]

On my way over now...

[K Simmonds]

Bloody hell you lads have been busy
Did you use the Metal Ready etch before painting the POR15?

I do have some but I didn't bother, the chassis paint in the arches doesn't require it and despite looking shiny the wishbone had plenty of 'rust pores' for the paint to take to. Apart from on new metal I don't find it makes much difference.

[80Quattro]

With the AC compressor, make sure you put the shims that came out back in between the front shoe and the pulley and thread lock the bolt, they come off more often than you would think. It looks as though it hasn't run for quite a while from the pitting on the surface so I would consider refacing both parts if you have a lathe. If not they will very likely be absolutely fine as they have always run together. You can easily test the clutch coil by putting 12v to it, it is a reasonably strong electromagnet and they rarely fail (unless you have a Vauxhall Astra!) Has the compressor been on a car and part of a sealed system? If it has been left open for any amount of time it is really important that you flush all the old oil out as it absorbs moisture very quickly. If it is a complete retrofit you will need to fill the compressor with the correct amount of oil for the whole system, if it's a vane compressor this might not be possible, but make a note of how much you've added as the rest will have to be put in when it's gassed up.

I used to be an AC Tech so feel free to ask any questions and apologies if I've just restated what you already know.

[K Simmonds]

With the AC compressor, make sure you put the shims that came out back in between the front shoe and the pulley and thread lock the bolt, they come off more often than you would think. It looks as though it hasn't run for quite a while from the pitting on the surface so I would consider refacing both parts if you have a lathe. If not they will very likely be absolutely fine as they have always run together. You can easily test the clutch coil by putting 12v to it, it is a reasonably strong electromagnet and they rarely fail (unless you have a Vauxhall Astra!) Has the compressor been on a car and part of a sealed system? If it has been left open for any amount of time it is really important that you flush all the old oil out as it absorbs moisture very quickly. If it is a complete retrofit you will need to fill the compressor with the correct amount of oil for the whole system, if it's a vane compressor this might not be possible, but make a note of how much you've added as the rest will have to be put in when it's gassed up.

I used to be an AC Tech so feel free to ask any questions and apologies if I've just restated what you already know.

Cheer's for the info, it's going to get a further clean with a wire wheel before it goes on my car so I'm sure it'll be fine.

There was just the one shim fitted and I've put it safe along with the little felt ring.

The pump on my car hasn't been disturbed and is still part of the sealed system, so I'm hopeful the pulley and a re-gas will sort it.

Will drop you a PM if I have any more questions.

[cardcrash]

Take some grubby springs:


Throw them in a vice:


Clean with wire brush:


Prep for painting:


One:


...and two...


...and start again with suspension mounts:


Clean:


...and colour:


...and over again with some struts:


Shove 'em in a vice:


Slap on the Ronseal!:

[hunker7]

What paint are you using? Looks really good

[cardcrash]

POR 15

[K Simmonds]

Yeah, we're using a thick coat or two of regular Por 15 on the suspension components, the springs are an experiment to see what the stuff works like on them.

The rear arches themselves I coated with Por Chassis specific paint, great stuff, dries faster than regular Por and is a joy to apply, finds it's way into any rusty seems. 250ml was just enough to do a good job of both complete rear arches with the liners out. Will do the fronts with the same stuff, would have done it now but I only had the one tin of chassis paint and it's all back together now.

Still it'll b coming apart again soon to install a matched set of springs from another RS2 as well as new bump stops etc.

I also have a couple of types of rattle can spray Wax oil to apply behind the arch liners, will see which works best and report back.

Got the nice job of bolting it back together today, then at last my S2 is going to be getting it's SRE clutch installed.

Figured that whilst it was all apart I'd do a proper job and paint everything, especially as I had the help of my assistant who seems keen on cleaning stuff with a wire wheel in a drill. Your help is much appreciated mate, has saved me a ton of time and the pic's are great

[K Simmonds]

Finally got a chance to get the back end back together, I was going to take more photo's but I got an unexpected visitor who slowed my progress and I just wanted to get her sat on the wheels so the springs can settle.

Anyway, assembling a rear strut, put the damper through the spring before putting the compressors on otherwise it the damper won't fit inside the spring. I also used a good amount of rubber grease on the bottom spring mounts so they could rotate and allow the springs to seat easily.







Now looks like this and drives like a different car, it needs proper aliment but I'd say I've got it pretty dam close, certainly fine for a couple of hundred miles to let it settle.

[irishs2]

Awesome. Have to agree it looks better too at the proper height.

[Vorsprung durch Technik]

Good work Kit.So you say she drives like a different car.Been there and done that with ALL new genuine Audi Bushes, shocks, ball joints track rods etc etc.Go on then how different? I would say you must have a big grin but you will need to describe that.

[cardcrash]

Forgot to put up your orange hoses:

[Error404]

What's different about the orange RS2 hose then? Is it made out of that nomex hose like the little one from the wastegate to the N75?

[K Simmonds]

Cheers Eric, I reckon it looks better as well, Mark it's like driving a car designed by engineers as opposed to one interfered with by monkeys, I'm really not a fan of lowering cars unless their going to spend all their time on the track.

Yeah Alex the orange RS2 turbo/IC hose is of much the same construction as the Nomex waste-gate hose, much tougher than a normal ABY item. This one is in excellent condition, nice one for cleaning it Charlie.

[Vorsprung durch Technik]

Mark it's like driving a car designed by engineers as opposed to one interfered with by monkeys.

**ck those interfering monkeys. You got me in stiches!! Those monkeys understand nothing but bananas.

When i did mine it was.....well....like driving a new car.The difference is huge.


My next door neighbour is going to think there are monkeys in the loft when i get out my Original leather 80 front seats out of the small loft hatch in a minuite.I just removed the Recaro Sports seats AKA RS2 seats.