S2 Avant -93

[Antsa]

I used the 3M 08800 as a coating on top of a epoxy primer. After that, I used 3M urethane sealer on the body seams. If I recall corrctly, it took about 12 bags of the 08800 to do the underside and the wheel housings.

The sills are just painted since they will be covered inside plastic trim.

[Tom_]

Tip over jig is now completed

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And it works too!


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I also added some small wheels to it so can move it around more easily. Its a useful feature since now I can push the car outside so its out of the way if I need to clean the garage.


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Thats all for now. There is going to be a little break for these updates, my summer holiday is over and I have to service both daily drivers before I can get back to working on Audi

What a lovely jig...could you share more info regarding dimensions ? Really nice project and topic

[Antsa]

Hi mate

No exact dimensions available right now, it is just right size rectangular pipe inside rear chassis rails and round pipe inside front rails. Both have 8mm thick steel plates at the end, which the vertical wooden support bolts onto

[YELL MAN]

Thanks for the info, just what I needed to hear . Hopefully going to spray epoxy this weekend after stripping the bottom, that wasn't enjoyable.

[Antsa]

Yep, removing all old undercoating is time consuming work

[Antsa]

Almost a month since last update A lot of sorting out little bits and thinking of best way to go on.

At least I got the trim installed that follows the roof. ETKA calls for this 'protctive film' under the stainless clips.


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The clips are riveted in place with stainless rivets


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Trim installed


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All driveshafts were cleaned and painted.


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Rear shafts also got new inner GKN cv's and OE boots.


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And installed


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[Antsa]

Fuel lines installed. Just to see that I have made a mistake. The feed line is kind of in the way of the engine sub harness connector bracket. I might be able to install all the connectors to the bracket by just pulling the fuel line out of the way by hand, but I think I'm going to do a few more bends so I can get the line to run a bit higher and closer to firewall.

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The bracket still needs a clean and paint. I will also modify it by cutting out the ingition amplifier mounting points.



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Even though the fuel system is not completely ready, I couldn't resist doing a leak test. This test covers the section from fuel tank bulkhead to the end of the hard line in the engine bay. System got charged to 9 bar.


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After about five hours the pressure was 8.8 bar. I'm calling this good enough. My self made test setup has two hose connections secured with jubilee clips and at least six threaded connections sealed with ptfe tape, so plenty of sources for small leak outside the fuel system itself.



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I bought myself a 20ton press to fit the wheel bearings. Bearings were easy to install with the press, but hubs were easier to install this way. The press serves as an excellent subtitute for a vise.


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All bearings and hubs in place. Mating surface for the hub and wheels is left untreated. Small touch up paint has to be done before installing.


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[Antsa]

Brake lines all finally done today. Took way much longer than I thought. Press comes in handy again for holding the flaring tool.


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These are the lines around the front strut and behind rear lower arm. Can't install them since I don't have brake hoses yet. I will have to do a test fit on the calipers so I can measure and make an order on custom hoses.



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Abs pump, brake booster and master cylinder in place


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All wiring harnesses that go through the bulkhead are in place.



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Pedalbox and streering column in. Pedals have new rubbers.



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One of my front arms was missing the press fit bolt



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So I got this (857407175)



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The bolt was easily pressed out



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The lengt of the knurled area is a bit short compared to the original 893407745A.



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Here it's installed. Went in easily with the press. I quickly tried torquing a balljoint to the arm and the knurling didn't slip even if it's shorter than original.



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[YELL MAN]

Art

[Antsa]

Fuel pipes got sorted with few additional bends. I'm going to modify the connector bracket and add one more fuel pipe support.



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Then it was time to move onto the sunroof. It has glue stains from headliner.



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I attacked it with cordless drill and a toffee wheel


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After cleaning it was time to disassemble the sunroof mechanism.


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New slide/guide pieces



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And then everything was lubed up using special grease



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Motor installed and wired to a car battery for testing


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And it works!


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And it's in

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[Tractor Dave]

Nice work
Note that the black screw down panel that covers the wire either side needs some tiger seal in places otherwise it will leak in heavy rain. I found out the hard way

[Antsa]

Then I moved on to electrical stuff. Butyl cord for sealing the fuse box frame to chassis.



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It's nice to have the fuse box like this. Much more comfortable working position than under the dashboard.



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This grommet was broken so I got a new one. Pretty hard to install on the assembled harness however. Every connector had to be depinned and then all the wiring was wrapped in masking tape and lubed. This worked out ok.



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All the way in. This was over a two hour job. It included some fiddling with the connectors since I only have cheap tool for terminal removal.


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Then it was time to sort out the loom for doors, window lifters and central locking.


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Looks a bit messy but hopefully it will be better when I can tie up the harness. Now I'll have to wait for the harness ties to arrive.



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[Antsa]

Nice work
Note that the black screw down panel that covers the wire either side needs some tiger seal in places otherwise it will leak in heavy rain. I found out the hard way

Thanks for the tip Dave I'll have to make sure it seals correctly.

[Nuvo]

This grommet was broken so I got a new one. Pretty hard to install on the assebled harness however. Every connector had to be depinned and then all the wiring was wrapped in masking tape and lubed. This worked out ok.



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All the way in. This was over a two hour job. It included some fiddling with the connectors since I only have cheap tool for terminal removal.

That must have been a complete pain in the *** to do, worth it in the end though. Brilliant effort all round Sir.

[Antsa]

It was a little head scratcher at first, but the masking tape and grease made it much easier than trying to pull the whole harness through the grommet without any lubrication. My cheap set of terminal removal tools was propably the worst part of this

I had broken wires right at this point of the harness that I repaired some time ago. I only wrapped them in harness tape then but since the grommet was available, I thought it was worth doing properly this time.