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Every 5 cyl block I have stripped you can clearly see the hone marks, even with a decent wear ridge at the top of the bores.
Alex you need to get to the bottom of why the HG blew in the first place. On the old gasket you can see evidence of where it has blown on the fire ring Cyl 1, if you do not have flat head or deck surfaces it will just do it again. Worth getting it checked while its in bits
Im sending the head off this friday to South Wales Pistons to have a pressure test, skim and clean up. Also one of the exhaust manifold stud snapped off flush to the head so ill get them to sort that out too.
As ive mentioned, the turbo water feed pipe had basically fallen apart too so that didnt help - on removing it it fell to pieces.
Get the proper Audi hose or more ideally the Samco hose - not sure of the size, it was in the Samco coolant hose kit. I spent ages trying to get a good fitting hose, ended up with 12mm I think which still wasn't quite tight enough of a fit. That soon got manky and started leaking too.... Just checked it today (has the Samco hose on my RS2) looks fine after 7 years of use.
I was thinking exactly this, something butch as a replacement. Samco surely will be man enough but I was also thinking of perhaps some sort of heat wrap because the heat under there seems to be regularly taking these pipes out.
Also as ill be replacing every jubilee clip, is there a preferred brand? The cheapie Halfords kind just dont look up to the job.
You have already done most of the work taking the head of. Not much more work to take the block out and get it checked , and if need be get the deck skimmed. That way you will be sure. If you have been using sandpaper on the block that's not a good idea.You need to be very careful about cleanness.
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