S2 Avant -93

[Tractor Dave]

Its very difficult to fit the sunroof panel with the foam backed material. I just managed it with the Nothelle project but haven't managed to get the rs2 one in ( yet). I think I'm going to re cover it and shave the foam around the edge and have another go.
Yours is looking good

[Antsa]

Headlining was fitted. Looks much better than the old one. It took two tries to make it line up properly, but now everything aligns as should. Sun vizors also got new bulbs behind the mirrors.

Regarding the sunroof and how much it should open. I can't remember myself how far back it went before starting the project, but since everything is zeroed and I can't find anything wrong with the motor or the limit switches, I think the above picture shows the full back position.

Sunroof cover is made with slightly different fabric than the headlining itself, because the fabric used in the headlining doesn't come without the foam backing. I don't think the difference is too bad.


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[Antsa]

Thanks for that. I asked about this a few days back on the facebook group, and was replied with a picture where the sunroof was all the way in the back. Now I'm confused I'm currently looking at the sunroof motor and can't find anything wrong with it.

[Ryan80]

I have a feeling thats as far back as the sunroof goes? Mine currently only tilts and wont go back, but my old tdi 15 years ago only went back that far.

[Antsa]

Brake dust shields complete. This is first times for me trying to make something out of sheet metal. They are not very pretty, but if they help me pass mot, they are good enough.

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Everything is back from the upholstery place. Before fitting any doorcards or headliner, I wanted to make sure one more time that everything works as they should. I'm glad I did. First thing was the that the mirror heating didn't work at all. The connector at the bottom of the mirror turned out to be the culprit. After cleaning the contact surfaces they are all good now.


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Then I went to test the sunroof. I've zeroed the sliding mechanism and the motor as per the factory manual. The tilting position seems good but I think the sunroof should go a little bit more further back? I'll have to investigate this further.


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[John.]

Those studded tyres look the business !

[Antsa]

Headliner and front seats are now at the upholsterer, hopefully they are back within a month or so. While waiting for the interior parts I couldn't resist trying on the front brakes. This is just a trial fit and the disk is on the wrong side but I think the brakes look great


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Brakes need to have dust shields for mot so I have to make them. This is template made from cardboard so I can cut some sheet metal to size and begin forming some kind of shape to it.


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While working on the dust shields my bespoke brake hoses arrived. I wasted no time fitting them.


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Now I will have to finish the dust shields and then I can fit the disks and pads and then bleed the brakes.

[Antsa]

One of my front fender trims was missing the plastic screw. Again it was my friend with a 3D printer to the rescue. Part fits perfect and the trim stays securely in place now


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All doors are in place. Panel gaps adjusted. Driver side fender is waiting for the Audi sign. Also lower trim is missing, because after it is put in place, there is no removing the lower screws that hold the fender against the A-pillar. I want to be 100% sure of the fitment before installing the trim. Passenger side fender is waiting for a side blinker and then it can be fitted too.


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Rear seat in place


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And dashboard also in. It is starting to look like a car again.


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Also some fuel system upgrades. Walbro was fitted into old pump basket.


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Nuke fuel filter was installed in the spare wheel well. I had to make a new bulkhead for the hoses to pass through. Not the prettiest, but ok. Ignore the rusty screws, this was just a test fit and will be replaced.


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[Antsa]

Middle door trims, new front hinges, slam panel and IC cross member were painted a couple days back.


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They look good now.


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Double sided tape to fit them onto the doors.


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Installed. This has to go right the first time. That double sided tape grabs immidiately.


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Door installed with new additional seal.


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Clips for the lower trim also in place.


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Front door install next and then I can start on the panel gap adjustment. Should be fun

[Antsa]

Plastic sill covers installed. These mounting plugs had to trimmed to fit them.


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Double sided tape for installing the top cover


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Finished install. These were also treated with ceramic coating meant for plastic parts.


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Now waiting for better weather so i can push the car outside and paint the remaining trim pieces and door handles.


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[Antsa]

Final polishing for the rear quarters, bootlid and roof is finally done The weather has been a bit poor so no shiny pictures in sunlight yet.

Some smaller jobs also completed. The driver side plastic rear wheel liner had gone so brittle it was unusable. OE ones are hard to come by so I bought an aftermarket one meant for fwd car. With a little bit of cutting it could be fitted inside the wheel arch. Fitment is okay for aftermarket part.


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Headliner cleaned together with the driver door card. Both front seats also stripped and ready to be taken to the upholsterer. Both backrest frames have a little bit of play but I got a new one for driver side from tradition at 85% dicount!


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[Antsa]

A month since last update, nothing major has happened. I had to buy new front door hinges due the old ones being loose. These have been prepared for paint along with middle door trims, slam panel, IC cross piping and door handles.

Sunroof was polished and installed

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Rear side glasses and rear glass were installed. The adhesive is pretty thick at room temperature and it's hard to push out using hand held caulking gun. Putting the cartridge in hot water before applying helps a lot.


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Side glasses on with new seals



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[Filip_FIN]

Very nice as always

[Antsa]

Ac airbox is in together with the carpet


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Old battery mounting cable was very stiff and it had a couple of strands cut at battery terminal end.


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So I had to make a new one. Deutsch battery terminal and hi-flex cable.


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Now the battery cable crimps to be done properly requires a hexagonal crimp tool. I don't have one. Instead I have a tool that is meant to be hit with a hammer. I used it in the press. Doesn't fill any standards bot got the job done.


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Some adhesive lined heatshrink tubing added to the terminal ends and it's the battery mounting cable done.


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[Antsa]

All the wiring looms are now in the car. All old tape that didn't hold on anymore was removed and new tape applied. This a pile of old tape from the wiring looms

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After that the airbox was fixed, it had a couple of broken tabs. 3M plastic adhesive for polypropyle worked fine here.



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Then it was time to plug in all wiring and control units and see that everything works before covering all the wiring under the interior carpet.


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At first I didn't have any comms with the aircon unit and ecu. The cause was that the ecu harness earthing points were not bolted to the chassis but they were hanging free After grounding them properly I was able to reach all control units with vcds. Also lights and window lifters work plus the central locking pump too! Charging light was not illuminating in the instrument cluster, but that was also due the alternator not being grounded properly.

Next I will have to clean the floor thoroughly, put the carpet in and install the airbox.