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TurboTy
Knows a Bit


Car: Audi S4 B5
Power: 330
Torque: 517 nm

Joined: 05 Jan 2016
Posts: 206

Location: Dorset

PostPosted: Tue Feb 09, 2016 9:57 pm  Reply with quoteBack to top

Hi everyone,

I been lurking around on here for the last few months and bar an introductory post and a panic post after breaking down i've been fairly quiet. Lots of good info on here, dangerous though as the to-do list is getting bigger everyday!

Anyway thought i'd start with something that isn't an Audi, promise it wont take long.

The Audi isnt my first 4 wheel drive vehicle as such, spent most of my teenage years around land rovers (weird referring to my teenage years as im only 22 now). Dad had a 90 and modded it over the years for off-roading, the usual big wheels, roll cage, lifted it, winch, etc and was actually the vehicle I learnt to drive in. Learning clutch control in that thing was an uphill struggle! After 10 years or so Dad had enough and sold up.

I grew up a bit and wanted to start trialing off road again but on a very tight budget. Bought myself a Discovery 3.9 V8 Auto for a steel as below:



Trouble with a Discovery is there is a lot of glass and bodywork which gets in the way:



Problem solved, spent the next 9 months or so making the body work look right and then wrapping a roll cage around it:





And one of her in action:



Did eventually get around to chequer plating the tray back and named her Poly, short for Poly-filler. A clue to how well some of the body work went
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Professor Peach
Skilled


Car: 2016 S3 Quattro

Joined: 17 Dec 2010
Posts: 1604

Location: Northampton

PostPosted: Tue Feb 09, 2016 10:11 pm Reply with quoteBack to top

My son is loving this Ty. I quite fancy having a go too.

_________________
Rob

All too often, the light at the end of the tunnel is a headlamp on the front of the on-coming train of disappointment.

When designing something to be fool proof, never underestimate the ingenuity of fools.
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Kent
Skilled



Joined: 22 Sep 2012
Posts: 1502


PostPosted: Tue Feb 09, 2016 10:13 pm Reply with quoteBack to top

That is cool. Not a fan of off roading (maybe i am i wouldn't now i've never done it propperly) but i like stuff thats been chopped up!

Fancy doing myself an 8l s3 pick up truck.

_________________
My S4 Widebody Build - RS4 engine about to go in... http://audisrs.com/about51237.html
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Challice
Experienced


Car: S4 V8
Power: 340bhp
Torque: 301lbft

Joined: 05 Mar 2011
Posts: 3017

Location: Wiltshire

PostPosted: Tue Feb 09, 2016 10:35 pm Reply with quoteBack to top

That's awesome, looks well built, I had a 300tdi for 5yrs fantastic vehicle, if it wasn't full of rust is still have it.
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TurboTy
Knows a Bit


Car: Audi S4 B5
Power: 330
Torque: 517 nm

Joined: 05 Jan 2016
Posts: 206

Location: Dorset

PostPosted: Tue Feb 09, 2016 10:59 pm Reply with quoteBack to top

Update on the S4 then;

Bought this back in December:



A high miler, looks like it was a business car for most of its life, many motorway miles but a perfect service history, 160k and still pulling well on original turbos (I'm saving for the day they do die!). Its had some good modifications already, RS4 seats and carbon interior, RS6 19 wheels, H&R springs, MRC remap, and a bunch of braces and stabalisers underneath. Reasonably rust free with the worst of it being on the rear boot plinth which should be an easy fix once the weather warms up.

Drives very well and feels tight for an old car. A couple things Ive sorted in the last few months.

First thing was to sort out the audio, the orignal audio system had been replaced with a nice aftermarket set-up. Trouble is half the kit was taken out by the previous owner. Left me with one amp (after some digging I found out there were two), a nicely fitting sub, and some component speakers in the front door cards. I bought a new Sony Bluetooth headunit and had to run new wiring to the speakers, after a lot of messing around I got the amp and sub working as well, took me ages to find out one of the wires in the sub had broken free



The H&R springs gave it a great stance, but they seems to be on standard shocks which i think died. The ride was very bouncey!
Bought myself a set of coilovers for christmas, ST coilovers made by KW (I'm pretty sure every coilover is made by them! ) Fitted them over a weekend, fronts were a bit of a pain until i realised I was fighting the anti-roll bar. Undid the other side of the roll bar and it all came out no problems. The rear shock turrets are looking a little worse for wear, I have another set ready to go on but I'm tempted to drop the whole rear end to re-bush and re-furb.



Out with the old:



Rusted out:



Fortunately the body is ok underneath:



Fine tuning the stance after giving them a week to settle:





At the same time, she needed a new set of rear tyres. The fronts had loads of tread left but were more of a budget tyre. Went all out and put a full set of Goodyear Eagle F1 Asym 2s and got it four wheel aligned at the same time. Completely transformed the car, couldn't be happy with the way it drives!


Last edited by TurboTy on Tue Feb 09, 2016 11:10 pm; edited 1 time in total
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TurboTy
Knows a Bit


Car: Audi S4 B5
Power: 330
Torque: 517 nm

Joined: 05 Jan 2016
Posts: 206

Location: Dorset

PostPosted: Tue Feb 09, 2016 11:07 pm Reply with quoteBack to top

Professor Peach wrote:
My son is loving this Ty. I quite fancy having a go too.


It's a lot of fun, and compared to most motorsport it really doesnt cost a lot.

Kent wrote:
That is cool. Not a fan of off roading (maybe i am i wouldn't now i've never done it propperly) but i like stuff thats been chopped up!

Fancy doing myself an 8l s3 pick up truck.


An S3 pick up would certainly stand out! The hardest bit is getting the roof to look right!

Challice wrote:
That's awesome, looks well built, I had a 300tdi for 5yrs fantastic vehicle, if it wasn't full of rust is still have it.


I would have preferred the simplicity of a diesel but the V8s are literally half the price and auto (prefer the autos for off roading). I do feel bad that I cut up one of the only non-rusty Discos still around  
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TurboTy
Knows a Bit


Car: Audi S4 B5
Power: 330
Torque: 517 nm

Joined: 05 Jan 2016
Posts: 206

Location: Dorset

PostPosted: Fri Feb 26, 2016 7:54 pm Reply with quoteBack to top

Mini update:

Bought some upper turrets for the rear shocks as the current ones are rusted out. Putting off fitting them at the mo as I want to refurb the rear end all in one go.

Also bought some RS4 downpipes, in the process of gutting them but its a bit more of a PITA than I thought, will also need to weld some new flexi bits in them at some point. Surprisingly I am in no rush to try and fit them!

Anyway, actual update to the car... Bought some wiper arms from a Passat to upgrade from the regular wiper blades to the aero type ones. Look a load better and don't judder up the screen when wiping over 60mph

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TurboTy
Knows a Bit


Car: Audi S4 B5
Power: 330
Torque: 517 nm

Joined: 05 Jan 2016
Posts: 206

Location: Dorset

PostPosted: Wed May 04, 2016 10:44 am Reply with quoteBack to top

Another mini update:

These arrived yesterday from Romania    



Freshly painted, new seals and pistons.

Didnt quite realise how big these things are



With some trepidation, I managed to swap the link pipes and bleed nipples over as required for trailing callipers. The paint did make things tricky but fortunately I had a proper set of brake pipe spanners which reach around most of the union so didn't round anything off

Sid motorsport bolts also arrived. Great service and super quick turn around thanks Sid!

Also have some B6 rears on their way although another pay day or two will need to come around before I have all the parts together
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TurboTy
Knows a Bit


Car: Audi S4 B5
Power: 330
Torque: 517 nm

Joined: 05 Jan 2016
Posts: 206

Location: Dorset

PostPosted: Sun Jun 19, 2016 8:39 pm Reply with quoteBack to top

Bought a rear end refresh kit from Jason a month ago or so and finally I bit the bullet to get it fitted.

Mostly a PITA to do, I borrowed a 20 tonne press and thought it would be easy to push out the old ones and push in the new ones...      

I didn't take too many pictures whilst taking it apart, that was hard work due to everything being 17 years old and fairly rusty. The coilovers have only been on 6 months so some of it came apart nicely.



These have been out before... you'll see in my previous posts the holes in the rear shock towers, these will not be going back on the car, got some refurbed ones  



The Hand Brake cables took a bit of thought... they appear to be threaded through the lower wishbone from the caliper side up to the handbrake, I didn't fancy unthreading them through the whole car so instead had to break off part of the plastic sleeve going through the wishbone which allowed me to pull them out whilst in situ.

The rear ABS sensors were having none of it    the first bolt sheared off leaving enough of a stud to stop me twisting the sensors.. not a good start.
It didn't matter anyway as the sensor was stuck fast in the upright. Got frustrated with them not budging and eventually cut the cable... the other side wasn't any better although the bolt did come out this time. Ended up knocking the sensors out from the inside. I ground the offending bolt flat, centre punched, drill and tapped a new hole, one problem fixed. When I phone up TPS, they wanted 180 + VAT per sensor   ended up using eurocarparts but were still 75 a side... for a wire and a magnet!!!



All of the parts got a once over with a wire wheel on a drill to take any loose rust and paint off, the finish isn't great but i'm not overly fussed, it would have been nice to get them all blasted but can't afford any more time off the road!

Then began the fun of working out which sockets, combination of support plates, height of table etc... was needed for each bush. a lot of the bushes have a lip which sits against the suspension arm, great when pressing them in, a PITA for trying to get them out again!! Many hours with chisel and hammer did eventually solve the problem although most bushes came out in several pieces.

Anyway... starting to put some bushes in...



Didn't take long for that to go wrong!...



This is the outer bush on the upper wishbone ,not really sure why it didn't want to go in but because the outer metal sleeve is in two pieces and the only way to push it is by compressing the rubber first, it naturally wanted to splay out rather than push in    had enough of messing around with those two so ordered powerflex for these. 35 for two bushes  

The wheels bearings were an event... Definitely in need of doing as they were both dry and the off-side one had a lot of play in it. I always wondered if they were in need of doing but with all the diffs, drive shafts and cvs turning under there I couldn't tell if all that noise was normal or not... Will find out if they are any quieter once shes up and running again!

Couldn't press the hub out of the bearing as the flange was too big to fit inside the support table, fortunately a socket and a couple hits with the hammer knocked the outer race from the bearing and out came the hub. The outer race was off shortly after using a grinder. Getting the rest of the bearing out of the hub took most of the 20 tonnes the press had to offer... I guess there is a lot of surface area fighting back, it made some interesting noises and was quite jerky on the way out rather than smooth like usual. Working out how to support the whole thing also took some thought, there isn't much there but it is doable. I actually think changing the bearing on the car with a bearing pulled would be easier! Who knows...



Putting the new bearings in was also interesting as it took a while to get them in square, kept moving it around in the press to push the high side until they finally wanted to push in evenly. The bearings had been in the freezer for a few hours so I think that helped!

As all the suspension bits have been finished they've had two coats of POR15, I've read quite a few people recommending this paint so will see how good it is, I've not had much luck with hammerite so hope this is better!

Anyway things are starting to look shiney now...



Once suspension is all back together I have a set of B6 calipers as well as new discs and pads to fit. Been using tdiquattro's post from a couple years back to get all the relevant bits together so hopefully next week I'll get them fitted!

The 18z's still await fitting but I'm off to Morzine for a week as of Friday so won't have time to get them fitted... I'll be in the weird situation where I have upgraded rears brakes and std fronts  
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Glekke
Knows a Bit


Car: S4 B5
Power: stock
Torque: stock

Joined: 22 May 2013
Posts: 201

Location: Belgium

PostPosted: Sun Jun 19, 2016 9:59 pm Reply with quoteBack to top

that sub enclosure is awesome, any idea where the previous owner got it from? Or is it a custom box?
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TurboTy
Knows a Bit


Car: Audi S4 B5
Power: 330
Torque: 517 nm

Joined: 05 Jan 2016
Posts: 206

Location: Dorset

PostPosted: Wed Jun 22, 2016 9:28 pm Reply with quoteBack to top

Glekke wrote:
that sub enclosure is awesome, any idea where the previous owner got it from? Or is it a custom box?


Looks like a custom box, although a good one! Having said that, I've seen a couple others on here with similar set ups so perhaps you can buy them. Not very helpful I know!
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TurboTy
Knows a Bit


Car: Audi S4 B5
Power: 330
Torque: 517 nm

Joined: 05 Jan 2016
Posts: 206

Location: Dorset

PostPosted: Wed Jun 22, 2016 9:45 pm Reply with quoteBack to top

Pretty much done now, she is back on all four wheels   although not without putting up a fight!

First thing this morning, had to change a wheel bearing which I managed to fubar whilst putting the hub back in  

Then was greeted with a rounded off brake union, usually not a problem but this one was on the hard line that goes over the sub frame! I'm really in no hurry to replace that. Anyway, cut off the old brake line as close to the mount as I could and then drilled off the flare on the brake line.



This left me just enough line, the cut the new end square and re-flair the end remembering to put a new union on first!

Then it was mostly just a case of lining everything up, and bolting it all back together. Torqued it all up at the end with the suspension jacked up roughly where it would sit under compression to save the bushes. ABS sensors went in a lot easier than they came out and fortunately no ABS warnings so all must be good!



Finally it came time to get the B6 calipers and discs on! The PFL rear discs vs B6 S4 discs...







So after all that, all I needed to do was bleed the brakes and we're done... Used an easi-bleed system as I always do, pressurised the system to about 16 psi and heard a really loud bang/pop... turns out my brake reservoir couldn't handle the pressure and split   TPS want 60 for a new one  


Some lessons learnt:
1. Three things you need when working on these cars:
   I. Time / Space
   II. Money
   III. Another car
2. Don't bother trying to make a plan or stick to it, something will inevitably change those plans

Anyway, got the 18z to put on the front, after a week I'm looking forward to getting some more enjoyment out of her
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TurboTy
Knows a Bit


Car: Audi S4 B5
Power: 330
Torque: 517 nm

Joined: 05 Jan 2016
Posts: 206

Location: Dorset

PostPosted: Sun Jul 17, 2016 4:46 pm Reply with quoteBack to top

So with the Silverstone Classic coming up rather fast, it was time to get some outstanding jobs done.

First up was the 18z front upgrade, this has been on the cards for the last few months but for one reason or another I've not had the time to sit down and fit them.

Had all the parts collected for a while now:
- Brembo 18z calipers, bought from KillerBrakes completely refurbed and went for black to keep the more stealthy look
- Ferodo Premier 17z pads - FDB1625
- Brembo ML55 345mm discs
- HEL brake lines
- Pad fitting kit
- SID motorsport 16mm shoulder M14 bolts & nuts



First task was to get the discs centre bore opened up from 67mm to 68mm, I managed to pull a favour from work and got them milled to 68.0mm, fitted perfectly and feel fine on the road so happy they are centred. Stripped the old brakes off to measure up the hub for a precise fit. Fitting the disc requires removing some edges from the upright, a quick buzz with the grinder and all was good.



All bolted up to check fitment



Check out the pad difference between standard S4 and 17z



To frame the brakes correctly, I spent some time cleaning up the wheels properly whilst they were off. Starting with a water and brush wash, then used some alloy wheel cleaner and then finished off with glue and tar remover.  A before and nearly after.



And the car finally back on the ground.





Super happy with the brakes, the ABS now actually has to do its job and it was having an easy ride with the standard brakes!  

Thanks for reading!
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TurboTy
Knows a Bit


Car: Audi S4 B5
Power: 330
Torque: 517 nm

Joined: 05 Jan 2016
Posts: 206

Location: Dorset

PostPosted: Sun Jul 17, 2016 4:54 pm Reply with quoteBack to top

Another job to sort was the leaking cam cover gasket, this has been leaking ever since I bought the car but finally managed to get it sorted.

Was actually more straightforward than I expected...

Not many pictures I'm afraid:



FYI, this is what 166,000 miles and a good service history looks like:



One lesson learnt, do not drop ANYTHING in these engine bays! I dropped a 1/4" extension bar between the turbo and chassis leg which ended up on top of the engine mount. Absolute bitch to get out again!

Jobs left before Silverstone are now cosmetic (touch wood)...
- Rear boot plinth re-spray
- B & C exterior pillar caps re-spray
- Plasti-Dip chrome trip around outside of front grill
- Clean up rear wheels and probably give the fronts another quick once over
- Decontaminate, polish and seal car. Try to polish the turd!

Thanks for reading!
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kylebrady
knowledgeable


Car: Noggy s4 b5
Power: 334
Torque: 440

Joined: 09 Nov 2015
Posts: 326

Location: Salford/manchester

PostPosted: Sun Jul 17, 2016 5:24 pm Reply with quoteBack to top

Looking good mate
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