Audi S1.5 [OEM+] - (10-valve turbo B3 Coupé)

[LeafBox]

Sup guys (and gals?)

By the looks of it, old Audis are quiet popular around here, so I thought I'd make a good fit...
Quick background, this project has been going on for about a year already, and if you want to read all about that you can skim through this thread;
http://www.s2forum.com/forum/showthread.php?t=73706 (I recommend atleast checking out the last few post so you now what's going on right now)

If you don't want to sit through all that, the TLDR is;

The engine is already moved and running, just got the thing drivable with 5-lug and brake swap, getting ready for "building inspection."
And that "Some stupid decisions are on purpose, and some are swedish building rules"

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Some pictures, starting from way back when up until present.



















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And a few noteworthy videos...




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If anyone has any questions, please feel free to ask whatever. Happy to answer!

[loxxrider]

That car looks so clean! Welcome

[LeafBox]

That car looks so clean! Welcome

It has become a bit rough around the edges since back then (I sold it for a while, and the owner in between was not as... Careful, as me)
But still pretty solid considering the age! And I basicly have a full chassie restoration planned including paintjob so, It's only gonna get better

[DE80q]

Its nice to see another 20vt project around here. I actually forgot that the B3 Coupe was available with the NG in other parts of the world. Is there a reason you kept the CIS and didn't go EFI?

[LeafBox]

Its nice to see another 20vt project around here. I actually forgot that the B3 Coupe was available with the NG in other parts of the world. Is there a reason you kept the CIS and didn't go EFI?

"Some stupid decisions are on purpose, and some are swedish building rules"

Not allowed to change the engine management if I want it to be legal... Unless I start running E85, But then I get a whole new set of problems...
It's really stupid, and there's actually a pending change on that rule, but for the moment I'm stuck with it.

But after the car has finally been registered as a "rebuilt vehicle" I'll probably swap it out. It's technically still illegal, but by then I already have my "modified-stamp" and there no list on what mods was on the car when it passed registration so

(On a side note, I actually read your Bandit-threads several times right before I started doing my swap. You where the only one that even tried with the CIS, and I got so dissapointed when you tossed it, because then I could'nt cheat by stealing your solutions )

[LeafBox]

As good as done...

Sup guys and gals....
No welding this week, didn't get hold of any metal in time, so I only have a small update today.

Battery finally back in with the rug and all other crap.


I think the results are OK.
If I get a good opportunity to redo it in the future I have another idéa I want to try out. But until then, this is a finished chapter.


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While I had the paintcan at the ready I took a couple of minutes to touch up the floorpans.
The isolation had gotten wet, which made the old paint fall of.


Just like last time, the contrast between old/new paint is a bit much.
But also like the last time, this is never going to be seen by anyone (except maybe me again). So I'll live with it...


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I WILL get all everything I need for the welder during next week. And sooner rather than later, because after the stupid fender is welded, I only need to modify some intercooler-piping and fab a intake-pipe.
Because after that's done I can finally complete step 1 (of 4) of the registration process!

[LeafBox]

In lack of other things...

Long story short, bit of a weird work-week so no welding done.
Instead we've been doing some pretty unrelevant stuff, but I had a good oppertunity - Speakers

My local audio-shop had 33% off on speaker-packages. And they had the exact headunit and speakers I'd been looking at so.
Seemed like a good deal. I'll be getting a small sub in the future that I plan on fitting in the sparewheel tray with one of those tiny spares instead.

Audiophiles are probably wrinkeling their noses, but it's not like I'm building an audio-car


5'25" rear


Some massaging required to get them in to the stock fitting.


4" front


Such an stupid design in the front, but they seem to stay in place


Whole backseat back again!


Some really dirty panels


The little relay/connector tray(?) back again, which cleaned up the driver side quiet a bit!


Gotta install the heater and fan before I can hide the ECU/cables on th eother side.

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Since I'm planning on a new WG-spring and ECU-tune, I thought I'd install one these little guys. Since there is none stock.


Dumb to constantly slow the turbo down, and since I don't have MAF I'll just leave it open for now.


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I have nothing planned for next week. I'll try really hard to get the welding done though.
But I'll probably fit the heater/fan aswell so I can tidy up the passanger side.

Keep it real!

[LeafBox]

Santa!

Guess what! I've basicly not done a single thing this week either! :rolleyes:
I pretty much only finished up some wiring for the stereo (top priority!). And well, I put the dash back in so I could get a better look at where to hide some of th enew wiring.

But hey, atleast Santa showed up!

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So the stereo got all its wires done, including lowpass(?) AND microphone. Normally I wouldn't bother with the mic, but hey, I had time and the best oppertunity ever, so why not...
I'm pretty sure this is the best solution in regards to audio quality and hideability (Yes, I did make that word up)




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The dash did a HUGE difference, it totally looks like a car again. Ofc the heatercore and fan is back in there too.
There's definitely some room to play with for the wiring, I just need to find somewhere I can fit my hands aswell...




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Then Santa came by with a set of Ronal Bolero's! In the slightly rare 8x17" ET35 that has a "flat rim". I was pretty set on a pair of Avus's, which look fantastic in 18", but I just don't think they're quiet as striking in 17", can't put my finger on it, but I've been having second thoughts for a while.

Then these popped up on the swedish version of craigslist i guess, and the deep dish design that the ET35's have kinda reminds me of my old rims.
Gonna get some 215/45 tires (which I also had on my old rims) for that mini-stretch and I think they'll look top notch

But they are kinda worn at the moment, so some painting needs to be done. I'm thinking white, which ofc is a bitch to keep clean, but the whole car is white, so it needs to be washed daily anyhow




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And guys, merry christmas :hurray:

[audifreakjim]

[LeafBox]

Vinterdvala

Sup guys, been quiet a while...
Just like most things, life gets in the way.

Me and the missus bought a new apartment that needed work, then work took over and lastly we had a family sickness to make time for.
But it looks like we're kinda back on track now.

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last time we where just messing around untill I could get the tools/time to weld the inner fender. And I'm happy to say that's finally over.
I don't have any pics of that today (maybe tomorrow), but it wasn't that interesting anyway

We did fix a few other things though, and I can show you what's going on with that.
Firstly we modified the intercooler piping since I wasn't 100% happy with it. And we needed to make way for the new BOV anyway so.

OLD


NEW

Bad pics, but the intercooler itself is straighter than before, also the bung for tempsensor has benn moved to the side of the pipe and turned the "correct" way.
The pipes are also a tad further out than before, so I had to take a chunk out of the front, but I'm not done yet, so pics of that will also come tomorrow.




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And since we now need somewhere for the BOV to circle back to, we went ahead and made a proper custom intakepipe as well.
I was gonna make one anyway since the hose-thing we had was only a quick solution so I could do test-start.
So now we have 2.5" piping all the way from the "igloo" to the intake



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AND NOW, THE BONUS ROUND!

FOR 1 INTERNETPOINT AND SOME EXTRA PROJECT-PICS!

WHAT, is this thing?



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Swim easy fishes... ><(((('>

[lorge1989]

The car looks amazing. Im going to guess your mystery piece is ducting for the intake, with the mouth reaching down to the front bumper vents.

[LeafBox]

The car looks amazing. Im going to guess your mystery piece is ducting for the intake, with the mouth reaching down to the front bumper vents.

God damn, nice work man! You are correct!

[DE80q]

Very nice work! I love seeing this around here.

[LeafBox]

Very nice work! I love seeing this around here.

Very happy to hear!
I feel like I don't get as much feedback as other project because I'm not chasing horsepower with a 20vt

[dana]

hah, yea low HP builds are for your own glory, not for internet fame. Nothing wrong with that.

Trust me, I am extremely excited about my TDI build, that would be lucky to have 175hp. Nothing wrong with that, just don't expect it to create forum excitement like some of the 800+hp cars.

[DE80q]

Don't worry about the hunt for power. Just running a 1.8bar chip and spring should be a fun setup fr you. I'm looking to get more power out of my 20vt, but nothing too crazy.

[LeafBox]

hah, yea low HP builds are for your own glory, not for internet fame. Nothing wrong with that.
Trust me, I am extremely excited about my TDI build, that would be lucky to have 175hp. Nothing wrong with that, just don't expect it to create forum excitement like some of the 800+hp cars.

Don't worry about the hunt for power. Just running a 1.8bar chip and spring should be a fun setup fr you. I'm looking to get more power out of my 20vt, but nothing too crazy.

Oh, don't get me wrong. I know what I want, and 999hp is not it...
I just really appreciate people checking in and giving a thumbs up since I know am not doing anything "interesting..."

[LeafBox]

Ready!

Now the car is finally ready for "building-inspection" and I actually called the inspector last Friday.
No date set yet since he was going to do a couple of cars in the area soon, but it shouldn't be to far off

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Anyway, this is the new inner fender. Moved out about 20-25mm and built this "bowl" for the preassure-dampener.




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And here's a pic of the intercooler pipe with the new front-plate-thingey.



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I put the car together (again) today, was gonna start her up but the battery was flat so I put the charger on it.
Thought I'd go back tomorrow, fire her up, switch rims and take some cool pics.

Then I'd better get home and bake something nice to butter up the inspector with

[LeafBox]

Now the inspection-guy just needs to show up...

[LeafBox]

Picture Dump

Nothing new I'm afraid, still waiting for the inspector. Mailed him earlier to check up, so hopefully we can soon continue.
But I had to move her a bit today, so I took some pics.

[lorge1989]

Looking good!

[LeafBox]

Looking good!

Thanks man!
I just want to get the damn registration-process over with so I can begin with the actual restoration!

[LeafBox]

Status

It's been a while since anything happened here, but I thought I'd give you guys an update.
The inspection-guy still hasn't been here, which kinda locks me down. But 2 emails and a phonecall later I learned that he's supposed to show up right after easter.

Realistically that's probably the first week in April. Kinda bummer that it has taken so long, if I'd know that before I'd planned things differently...
Since I'm planning on being road-legal by the end of May, and there's a $h!t-ton work and legal-hoops to jump through.

Now that I knew I had a bit of time left until he showed up I took care of some very minor things.
First up was the exhaust, it needed a cat since the stock one was emptied, so i just slapped something together since I'm gonna remove it after the inspection again.
Not much to show right now, but I did snap one pic.

Then I made a crank-pulley-special-tool-thing to be able to torque some serious newtons after I've replaced the front oil-seal.
It's leaking more than I'm comfortable with, and soon will probably be my best oppertunity.

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Plugged lambda hole since the MC has it in the downpipe.


Gotta excuse my welding here, I used an old stick welder which I'm not the best at :hehe:


Old NG crank-pulley for testing.


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Since I now have basically wasted quiet a bit of time waiting around I decided to try to make up future time.
I've decided that I'm gonna complete (almost) everything from the windscreen and forwards (apart from the subframe), so I don't have to (hopefully) remove the engine any more.

So I've started stockpiling parts ahead of time to cut down on delivery times. So I've got a ton of stuff on its way home.
Mostly gaskets and stuff, but also some pretty sweet 034 motor-mounts, strut-bearings and small goodies.

Which should provide for the pretty high tempo needed to reach our goals within the timeline.

[LeafBox]

Easter

How many did some easter crafting?

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Done with the pulley-tool.



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Also tore down the rear brakes, since they are probably gonna be more useful when they move...

Yuck...


Totally done for, I only installed them last time to get the wheels on for the move.


That one odd disc with a spacer, wish I knew the story here...


Didn't get new stuff installed because there was some confusion at the parts-store.

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I guess I'll have some more brake-pics during the week, then we'll have to wait and see what the inspector says before moving on and tearing it down again

[LeafBox]

STOP!

Not only can we start, go forwards AND backwards. But now we can even stop!
It was a tough nut to crack, but we got there.

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Since i was going to give the rear brakes the same treatment as the fronts. Complete with discs, pads and restoring the calipers.
So while I was removing the calipers I rounded off a brake hose. No biggie, I'll just switch them to since I'm here, and they were questionable anyway.

'JUST'
You guys that live in a place where they salt the roads know the drill.
It ended with basically new everything for the whole rear end

6h later...


Cleaner if nothing else...


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But in the end I actually got to do what I came there to do...

Sandblaster action


Eat it Picasso



Some of you are probably aware of Audi's backasswards handbrake mechanism...
And there's this 'little' spring inside the caliper that pulls the piston back, which is secured by a lock ring at the base.

You can barely compress the spring enough when you have the thing in your hand, so how the hell are you supposed to do it INSIDE the caliper
while ALSO TRYING TO FIT A PLIER!? I'd like a talk with the designer on this one...

A lot of time and new spacial tools later..
img]http://i.imgur.com/DGMn9SP.jpg[/img]



Finally


Really disgusting shields, but they'll have to do until rear axle restoration.


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And that's that!
Not much else has happened. I got a bunch of packages!



Mostly gaskets, but a few goodies like 034Motorsport engine mounts, 'snub' mount, and strutbearings.
Also a oddly hard to find gearbox mount all the way from the UK.

Now it'll probably be quiet for a while 'til after the inspection, which should be this week.
See ya later!