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ScottR

Never Say Never Again - One DIY project too far...

So where do I start?
As you may be aware, I have previously done a couple of (mostly) successful engine pulls on my old car Blue Thunder (documented here), and the unfortunate decision made to eventually decommission her time lapse action here.

I was sad about the prospect of being without S/RS power in my life, but Mikey-S was selling the S4 he'd bought off Stigter earlier in the year.  A silver 2000 saloon.   It had a noisy turbo and needed some TLC to bring the cosmetics up to scratch, but it drove beautifully, was a good price and most importantly for me, didn't have some of the faults which soured my love of Blue Thunder, namely the fecking drivetrain shunt which i'd tried everything to get rid of.(remember this for later!!)  But as a man with K04's and all other supporting ancillaries sitting in a box in my garage, it was ideal for a 'cheap stop gap' car.  I had foolishly thought I could fit the K04's and minimum supporting mods to get it over 400bhp, give it a bit of spit and polish, then sell it on for the price of the car + the value of the bits I was putting on it from the old car, with the ultimate aim of breaking even, possibly even making a little money for my efforts.   That would show wifey what a "waste of money and time" these cars are!  But these cars have a habit of getting under your skin.  Then they make you make decisions.  Not always the wisest.  Then... you're theirs!!!

What follows in this thread?  A detailed documentation (there are over 500 photos... but I promise I won't subject you to all of them) of New Thunder's journey.  The highs, the lows, and all those bits in between which many of you will have seen in random posts,woven together in a joyous rich tapestry of AudiSRS at its best.   Disclaimer - This thread will require serious forum stamina.  Any willing participants who suffer from repetitive strain injury, ADHD, OCD or an aversion to seeing MacGuyver style techniques being used - this might not be for you.

I hope you enjoy reading this more than i've enjoyed many parts of 'the journey'.  
The title of my thread - "Never Say Never Again".  The reason for this shall become apparent as the story progresses....

One of the things which I found had seriously hindered my previous engine pulls was myself.  More specifically, my inability to organise my tools, eg: a sweary "Where the feck is that 17mm spanner I was only using 5 minutes ago?" was usually followed by 15 minutes of searching for the missing tool.  Often found in the first place I'd looked.  When dismantling the car, I literally had most of my tools thrown in a big box, which surprisingly helped a little.  Just because I didn't know where in the box the tool I wanted would be, there was at least an 85% chance that the tool I was looking for had been put back there.  But this was a problem I wanted to eliminate as best I could.  So I introduced some Noggy Blue into the equation.  
Thankfully Halfords were doing this for £100 at the time.  Another tenner from eBay for some drawer liner, and I was good to go (I highly recommend this toolbox, very sturdy, decent size and the right colour ):


Also bought a new jack, some more tools and some stuff to remove rust - Not far off another £200.  A sign of things to come...
Because my garage was completely full of crap from the dismantling of Blue Thunder, I had the dull task of tidying up a bit.  You'd never believe it, but this is it post-tidy!



I had some parts from Blue Thunder which I planned to fit, so I got busy with cleaning up some of the parts, and with my recent discovery of Hammerite (truly a gift from the gods), I planned to make bits look pretty as well as having removed any nasty rust.  First up, the rear brakes.  I had a set of Trig's brackets and B6 discs on the rear.  The calipers were looking a bit tired, and I'd also been driving round with red carriers for the last few years after having to swap my RS4 carriers for S4 carriers(thanks DavidT ).

The rear discs hardly had any wear, but both inside faces had a weird lip, which was odd given the front faces were fine.  Looks like crap has got trapped, then heated things up.  Each of the discs had a 'glazed ring' around the side of what I imagine must be very baked on brake dust.  I was able to use a wire wheel to clean up the light surface rust from where these had been standing, and thankfully, these 'beads' could be chipped off fairly easily.  You can see what I mean if you look at the 7-8 o'clock position on the right disc here.  The left disc had been given a going over.  After this pic was taken, I actually used an angle grinder to carefully clean the outer bit to make this flatter.  I didn't want the pitted surface destroying the new pads which were due to go on (and I can confirm that a couple of 1000 miles later, they are still nice and clean on the inside now!).

(being a tart, I also gave the front of the middles a lick of... you guessed it - silver Hammerite)

At  this point, I noticed the callipers themselves were not as free as I'd like, they were hard work to wind back.  So time for a strip down, clean up, rebuild with new seals and a lick of pretty paint.  

When I stripped them down, I noticed slight grazing to the piston and light scoring of the bores.  The fluid has obviously got contaminated at some point.





A fair bit of time cleaning them up then polishing the faces up with a Dremmel  and they were looking much better.

Ignore the alloy corrosion on the outside (this was all painstakingly scraped off after), this pic shows the bores having most of the big scratches cleaned up.


First coat of paint sorted

I also managed to Part Ex my old B7 RS4 fronts brakes with Mr.Bison for some newly refurbished B5 RS4 brakes.  One less job for me to do!  But who wants mismatched brakes? (ignore the previous bit about me driving round with red carriers for the last few years )


And finally lacquered with high temp engine lacquer


Refitting the seals and pistons into the rear brakes was a b*****d of a job.  It really was.  Never want to have to do that again, I don't have the patience.  It's a very tight fit!  I soaked the seals in brake fluid overnight beforehand.  The biggest faff is trying to get the dust boots fitted.  If you put them into the caliper housing first, it seems impossible to pull them up the piston (once you've wound it in).  So then you putting the boot into the piston groove first... but trying to pull the boot down the length of the piston reminded me of sex education classes and crusty old Mrs.Horne.  Gross.  Anyway, where was I?  Erm... ah yes, squeezing tight rubber into stuff.  My specialist subject.  Can't even remember how I finally did it, i'm fairly sure it was the first way I mentioned.  To reiterate - a b******d of a job!

So the brakes were done, and I think they were looking rather good.  But I couldn't rest there.  I'd only just begun .  Next up was my rear end (ooh err!).   I'd had all of the rear end rebushed on the old car within the last year.  Did plan on selling it all, but seemed more hassle than it was worth to package up and send such bulky items.  But what really sold me on the idea of fitting these was the shocking state of the underside of New Thunder.  Don't think i'd mentioned that.  I'm pretty sure a previous owner must have thought it was a boat and moored it up in a harbour somewhere.  

Here's a pic of the 'good' ones from Blue Thunder, after some serious wire brush action to get rid of the nasty stuff.

A few coats of the good stuff later...



By this stage I was getting good at the wire wheel/wire brushes/angle grinder (for the occasional tough cornflakes) and Hammertime action.  If some is good, then more is better!  I had the front subframe and relatively new front arms from Blue Thunder sitting there gathering dust.  You know the drill...
Nasty!

Crusty!


You can see once the crusty bits are wired off, it's all looking clean and solid under there

The other side



Tada! - Did a few coats all over .  Much better than how this one started.  Much, much, much better than the one it was due to replace!




Sick of all this painting nonsense?  Tough!  You were the one who started reading this thread! (I promise the paint photos are nearly finished... for now)



Looky what we have here (thanks to Jockthedog) - a refurbished box with a new shift hub, new synchros, seals, etc.  But it looked to shabby to be attached to my lovely shiny subframe, so...   Old gearbox paint vs. pressure washer, only going to be one winner there!

And after some wire brush based elbow grease it was ready for not one, but two flavours of delicious Hammerite!



First, a lovely full new coat of shiny silver.  


But I fancied something a little different.

What do you think of this little stunner?  


After I took that photo, I rode it like the weird cowboy pilot at the end of Dr.Strangelove.  Let's never speak of this again.  It's our little secret.




With most of the prep work finally done, the week I'd booked off work for the real action to begin was fast approaching.  

Tune in next time for the next exciting episode!
bboy82

You sir, have a lot more comic talent than a lot of stand up comedians!

I know exactly where you're coming from with the love/hate relationship that these cars can inflict upon us happy DIY'ers. I was, up until I drove it today, in a quandary over what to do with mine.... and then I promptly bought a FMIC kit after I got home!

Outstanding work thus far, and I for one am longing for more!

Jakub

bboy82 wrote:
You sir, have a lot more comic talent than a lot of stand up comedians!

I know exactly where you're coming from with the love/hate relationship that these cars can inflict upon us happy DIY'ers. I was, up until I drove it today, in a quandary over what to do with mine.... and then I promptly bought a FMIC kit after I got home!

Outstanding work thus far, and I for one am longing for more!



 

x2

Gone through a phase of motorcycles. Nearly sold the car. Then after not driving the S4 for 2 weeks, went for a spin. That was 2 and a bit months ago. Since then I've spent almost 3k on turbos, coolers, clutch blah blah my room is full of boxes now...
Fullraceken

Nice work Scott she's going to look mint
All my mate gave me some stick for painting my gearbox but I don't care because it looks lovely  
benh999

More more
Graham

Good to see another write up. Yours do make good reading! Moving to P&Bs...
guymcc

Cracking read so far!  Great effort!
ScottR

Graham wrote:
Good to see another write up. Yours do make good reading! Moving to P&Bs...


Thanks Graham.
Challice

Love the blue calipers  
Alps

Great work and entertaining write up. Looking forward to the enjoyment this build is going to give
DW

Great Sunday morning read Scott. Definitely comic genius with the colour of that gearbox - looks like a Bassets Liquorice Allsort. At least it won't be seen

I truly admire your perseverance but probably your wife's more looking at the state of the yard:D

Keep up the good work.
ScottR

DW wrote:
Great Sunday morning read Scott. Definitely comic genius with the colour of that gearbox - looks like a Bassets Liquorice Allsort. At least it won't be seen

I truly admire your perseverance but probably your wife's more looking at the state of the yard:D

Keep up the good work.


Cheeky!  The blue in the painted gearbox pic was the masking tape by the way.  

To be honest, the crap down the side of the house was nothing compared to the Dining Room, which for the previous 5 months had been home at various times to - bumpers (x3!), wheels, Recaro Interior, bootlid, many boxes of random crap, etc.  And not sure if you ever saw my 'pizza box paint booth', which also lived in the Dining Room!  

Just wait until you see what I did with the back garden...
DW

Yep, can't wait for the next installment.
frazz82

Good effort Scott. Love the write ups.
aidank1981

Hopefully this motivates us all! Great work!
rob_arthur

nice work, im currently restoring my s4 to its former glory and it takes so much time, effort and money but should be well worth in the end. except im not doing an engine pull. which would probably be easier as most other things are off.
valver

Great write up that, very detailed and informative!  
FalleN

That's a nice start, great to read and I can't wait for the rest to come
stigissimo

Re: Never Say Never Again - One DIY project too far...

ScottR wrote:

One of the things which I found had seriously hindered my previous engine pulls was myself.  More specifically, my inability to organise my tools, eg: a sweary "Where the feck is that 17mm spanner I was only using 5 minutes ago?" was usually followed by 15 minutes of searching for the missing tool.  


haha, happens all the time  
jockthedog

I got almost the same toolbox from Halfords myself, for that 99 quid price!
Mine is red and has a couple of rows of 1/3-width drawers.

Well worth it although I do find my 'tool wall' invaluable.
Trick is to keep putting everything back where you got it IMMEDIATELY when you stop using it.

I've lost a wheel bolt this weekend and I'm damned if I can find it ANYWHERE. Arrgh!
Kent

go on scott, you crazy kat!
ScottR

Kent wrote:
go on scott, you crazy kat!


You're just jealous of my fancy box paintwork and regretting going for the Darth's helmet look with yours!

Don't worry Kent, your 15 minutes of fame will be documented in my memoirs when I get a chance.
Kent

Big up the hammerite crew
Noggymike

Kent wrote:
Big up the hammerite crew



Brings a new meaning to


"Hammer time"
ScottR

DAY 1

I had also been accumulating parts for my 'zero budget build'.  Most annoying were bits I had sold from the old car, then decided I wished i'd not and ended up buying replacements... or in the case of my Bilstein B12 kit... buying them back off the people who bought them from me.  
For example, literally only weeks after selling my 034 tranny mounts, I started to feel a weird sensation occasionally when selecting first when the car was stationary.  It literally felt like the whole box was moving on the mounts.  Thought it was silly not to change them when I fitting a 'new' box.

The costs started to creep.
Gearbox - £ lots
Bilstein B12 kit - £350
034 Tranny mounts - £90
5 puck clutch plate - £160
Rocker Cover Gaskets - £80
Load of new gaskets, fluids, nuts and bolts from Audi  - £100's

But I wanted everything to be right.  Last thing I wanted was to put it all back together only to discover something I should have changed whilst it was all out.  



The big day had arrived.  May 15th.  Wifey was off on two back to back girly holidays (lucky for some!), giving me about 10 days to turn this ugly duckling into a fire breathing swan(turn the house into a scrapyard).  

I had it all planned out.  10 days was loads of time.  LOADS OF TIME!  It had taken me approx 7 hours to get the engine out of the last car on my own when I was dismantling it, so I figured I could practically build a Le Mans car from scratch in 10 days.  

Here is the list of tasks I'd planned to get boxed off in the 10 days:
• Engine Pull
• Fit K04's and pipework
• Fit RS4 Intercoolers
• Fit Injectors
• Fit Bosch 044 fuel pump
• Fit lovely new 'Liquorice Allsorts' Gearbox (beats the chocolate gearboxes in most S4's! )
• Fit Downpipes
• F-Hose and N249 delete
• Fit new Rocker Cover Gaskets
• Spark Plugs
• Replace front subframe
• Replace rear arms
• Fit B5 RS4 brakes up front
• Fit Trig's B6 setup to the rear
• Fit Exhaust
• Fit RS4 Oil Cooler
• Fit RS4 engine mounts + 034 Tranny mounts  + 034 Snub Mount
• Replace front wings (orginals bubbling to hell)
• Replace steering wheel
• Fit cluster with repaired DIS

Piece of p*ss for the IT professional who only 8 years ago took my car to Grizz to change a sidelight bulb because I didn't know how.  

Looking back on it, I really wish I had written that list out and just read it back to myself.  That's a lot of stuff to do for a fool!


Meanwhile, during the closing stages of this planning phase, something had caught my eye.   The infamous Red WB from Bradford.  After days of being bashed for the fake service history, the seller realised he'd been caught out and overpriced it, then offered it for £7.5k literally a day or two before Wifey was off.  It looked fantastic from the photos, it had to be worth a look.  Worst case scenario is that I've been able to take in the beautiful , historical and cultural city of Bradford :reallysarcasticemoticon:.  I'd thought to myself, if this red one was as good as it looked, I'd buy that, take it home, then use my huge 10 day project time to do a DOUBLE engine pull!  I'd whip the engine out of the red one, whack in all of the go faster bits from Blue Thunder (it's what she would have wanted), put it all back together, whip out New Thunder's engine, take the K03's from the low mileage WB and fit them, tidy her up and sell her on for a small profit.  I'd have a beauty of a K04'd WB, someone else would have a solid driving K03 silver S4 (i'd already started to address some of the cosmetics over the previous months).  Everyone would be a winner.

The day of reckoning.  I dropped Wifey off at Liverpool airport at stupid o'clock, then headed straight up the M62, Bradford bound.  Met up with Kent who very kindly offered to come and have a look at it with me.  Ideal given he was half way through his own DIY widebody project!  But let's not digress too much here, this thread is about New Thunder, not Red Thunder!  
A long story short - Kent's critical eye pointed out faults in the bodywork/paint in the Red WB which I simply would not have spotted.  It needed to go back to the paintshop.   I wasn't willing to buy it knowing it would have to get sorted as it could have cost megabucks to get a decent job done.  If Kent hadn't have gone there with me, this thread may never have happened.   It was absolutely stunning to look at, and aside from the quarter panels, it looked fantastic inside and out.  Then there was the test drive.  10 days wouldn't have had a fraction of the faults sorted!  So... NO SALE! (to be fair, if the body/paint were straight, I had all the mechanical bits from my old car to put it right so it would have been perfect)

Kent, I owe you a beer!


After my disappointment/relief, I headed back home.  A nice long journey to clear my head and start to run through the various tasks in my head.  This was going to be a doddle.

Anyway, enough yabbering.  Time for some photos!  

I decided to walk round the car, taking pics of all of the various annoyances with the car, so I could look back afterwards at what a great job I had done.  (yeah right!)

As I was sat there, it was the interior annoyances first:



Then the exterior tattyness:





Reminder... needs to look like this when it goes back together!


So whilst i've been faffing about going over to Bradford, taking photos and attempting a self-hypnosis engine pull, the best part of the day has gone.  It's 14:30.  

Shit!  Only 9.5 days left to go!    

Time to get busy!  After lunch, it was time to get busy.  Nearly 15:00 before I actually got my ass into gear!

Obligatory "just started" photo:


90 mins later I had it jacked up, shifter linkage disassembled (forgot this last time and nearly ended up pulling the car off the axle stands via the gearstick! ) and the front bumper was off.   What the hell had I been doing?  I'll tell you what... getting distracted every step of the way.  It's my curse.

Noticed a rather suspect coating of oil on the pass side intercooler.


And whilst time was ticking away, I thought - let's arrange a photoshoot to compare the sizes of the S4 intercooler shrouds versus the RS4 shrouds:


9.4 days left...

Underneath the car now, it was time to drain the coolant.  I was shocked at the colour of the crap that came out.  

Stigter had the cambelt done early last year, I'm entirely convinced the garage that did it reused the coolant!  (ignore the oily stuff, I'd previously used this bucket for oil)



Things didn't get much better when looking underneath the car.  
Oily sump.

Lots of rust and grime!




Engine and tranny mount bolts off, I was done with the underside for now.  It turned my attention to removing all of the stuff off the top end of the engine.

First job.  Bugger!

Thankfully, that was my worst boo boo on day one.  I was getting tired, but because of the late start, I wanted to keep going.  Made some reasonable progress.


Rusty Pipes and very grotty everything else.


Look how thick this crud is!


Bent down to remove the earth strap from underneath the chassis leg, go to stand up and...
Robot Wars' Razor decides to attack me from above!


Absolutely tw*tted my head and nearly knocked myself out.  I was done for the day!

It was 19:30.
BHZ661

Not bad proggress for day 1 , hard hat required from day 2 lol
david1980

stick with it, shame about the other car but at least you know and can trust this one
Noggymike

Shame the tw#t on the head never knocked some sense into you Scott
guymcc

Good work!  A great pics along the way!
ScottR

Noggymike wrote:
Shame the tw#t on the head never knocked some sense into you Scott


No chance of that happening!
david1980

so how are you getting on with the project?
ScottR

Lots more to come, just struggling for time to put the pics and words together. Will update in the next few days.
david1980

thanks, hope your keeping on track for the 10 day project
ScottR

DAY 2

An early start on Day 2, I had some catching up to do and wanted to post off a couple of bits.  My cluster was off to Jason for a new DIS, my ECU was off to Rick for a K04 base map.


By the time i'd got to the Post Office, bought a sickening load of red meat, beer and snacks (a rare opportunity to pig out on all the crap I like whilst Wifey is away!) and got home, it was already getting on for lunch time.

My first stint under the car was to drain the gearbox oil.  A lot of leaking from somewhere!


Some last pics of the baby brakes

And a shot of the tired looking wheel well


Next job was getting the driveshafts off the gearbox.  I came up with this cunning method.  Wedge a small crowbar in the disc vents and a wheel bolt to keep the brake disc attached to the hub to stop the driveshaft from turning.  I also found it useful to dig out every socket extension out so I wasn't fighting against the inner CV boot all the time!



And because i'm lazy...



Once they were dealt with, I disconnected the exhaust and gave it a ruddy good yank to disconnect it.  Just as well i've got a new one to fit, just look at the state of this!!!  (although to be fair, it's lasted 14 years and 130k)


And another couple of shots showing the state of the underside of the car:



Now at this point, I had a little scare.  

In fact, it was quite a big scare.  

I had disconnected the driveshafts, now it was time for the prop.  Whilst under the middle of the car, I started loosening the bolts.  I imagine by this point some of you are already beginning to wince.  1 by 1 the bolts came out, then the final one...   CREAK!  F*ck me, you've never seen a man slide himself out from underneath a car so quickly!  I don't know how the hell i'd done it, but somehow I had not left the handbrake on.  I had left the car in gear (I like the belt and braces approach... just need to remember the belt first next time!), but obviously with the prop disconnected, there was nothing to stop the rear wheels, and therefore the whole car moving!  

Spoiler alert - The car didn't fall down and squish me like a bug.

I didn't get a photo of the 2 axle stands holding the front of the car up and preventing the whole thing from rolling back, but believe me, it's not a sight I want to see again.  The arms were at a very uncomfortable angle!  But, I had come perilously close to a very nasty situation.  My pants were soiled.  I decided 2 hours was enough on the car for one day.


I packed up my tools (after pulling the handbrake up so that it was pointing to the stars!) and decided to spend the rest of my day doing something much safer.  Throwing myself down a mountain on 2 wheels.

Apologies for the boring update.  It does get better soon! (the frickin engine finally makes it out in the next exciting installment)
guymcc

Like you say!, you must have shat yourself!  Glad everything was ok!  Keep the updates coming! Very enjoyable and great photos!
Kent

Lucky dude! I think we've all probably had one of those scares at some point that changes how you look at things teaches you a lesson.

I use the same method from outside the car with driveshaft bolts although i can do it in two extensions not 67 haha (my extensions bigger than your extension).
BHZ661

Very lucky its amazing how quick you move when you have to  
david1980

wow very lucky, glad you are still here with us all. I unfortunately know of someone i've met and been friends with who was killed when his jack collapsed whilst he was under his car earlier this year.

I saw someone in a car park the other day with some big 4x4, front wheel off, car on a scissor jack/widow maker and he had nothing else under the car as back up. Certainly makes you think and worry.

Stay safe
Challice

Close call, glad nothing came of it...
bboy82

As soon as I take the wheels off, I slide them under the sills. It's not perfect, but it's better than sweet FA... Glad you're still with us bud.
jockthedog

(is it safe to come out yet?)

cripes Scott, you're a lucky man.
You coulda been under there for let's see, 9 3/4 days?
ScottR

DAY 3

Because i'd gone to North Wales mountain biking to calm my nerves, it meant that Day 3 had yet another late start.  So far I had managed a 15:00 start on Day 1, packing up after about 2 hours on Day 2, and another late afternoon start on Day 3.  The clock was ticking.  But the weather had been glorious.  Blue skies, baking sunshine, life was good.  I still had a week, there was plenty of time.  I'd just barely nibbled at my contingency.

I began with some lessons learned....  an extra pair of axle stands, just in case!


The back garden was chock full of prepped bits.  It was another lovely day.


It was about 14:00 before I got fired up and stuck in.  Started off checking everything was ready for lift off (out).  Heater matrix hoses were disconnected, shifter linkage was disconnected, all electrical stuff was detached from the body, mount bolts and earth straps were definitely removed...  I was ready.

Hooked up the engine hoist, triple checked everything again (more timewasting) and started the lump's gentle ascent.  This time I was going to try something different though.  As I had a lovely shiny subframe to fit, I decided I might as well lower mine.  This is something I had never bothered with in the past, but I had read that a lot of other people do like to do this as it "makes is much easier to pull the engine".  My personal view?  It makes very little difference!

Once the engine was out a few inches, I had to deal with my old nemesis.  The Clutch Slave Cylinder.  Oh how I hate that horrible little b***ard.  I hate it so much.  The last time I pulled an engine, I took great pleasure in cutting it off.  Unfortunately not an option this time.  

I spent about 90 mins trying to get the ****ing **** thing disconnected.   My neighbours were giving me disapproving looks from all the puffing, panting and swearing (it was windows open weather!), my hands and forearms were red, swollen and scratched to hell.  Looked like i'd been in a boxing match with a tiger.  I was ready to reach for the petrol and matches.

But at that moment, salvation arrived in an unexpected form.  Twas Stigter, forum regular and previous previous owner of the car.  He had come to see what I was doing with his old motor.  And unfortunately for him, he was about to get roped into some manual labour!  

But, being a good host, it's only polite to welcome visitors in the correct way.  It was time for a much needed brew.




The break had worked wonders.  I was now calm, collected and buzzing my tits off on caffeine.  Plus, and perhaps most importantly... I now had an audience.  Failure was not an option!

I can't remember exactly how much more swearing there was as I returned to the task of disconnecting the slave cylinder, but I do remember it was still lots.  

But it was worth it...  Success!!!  (that is some kind of grime on my forearm, not just bruising from the slave cylinder action)


At this point I can confirm that a second set of hands does make the actual engine pull easier.  Went with the tried and tested jack under the gearbox method.  In retrospect, knowing that the front subframe needed to come off anyway, it probably would have been far easier to just remove the subframe completely at this point whilst the engine/box were hanging from the engine crane... but  how often are people removing both at the same time.

But it was finally out.  And I had a disgusting engine bay to prove it.


Look at the grot



The dreaded twunt of a slave cylinder.  And no idea what the coloured stuff is...  Perhaps some arterial spray from my tussle with the slave!


More mucky engine pics



And the engine in it's new temporary lodgings.  I think it just winked at the lovely gearbox.  


The manky engine bay was upsetting me, so I had to give it a quick once over.  Yet more timewasting!


One thing I noticed at this point was that the heatshield 'protecting' the fuel lines to the engine bay was all but destroyed by rust... yet the one on the other side was perfect.  Weird!



It was 19:00.  Only 5 hours managed today, about 2 of that wasted on the fricking slave cylinder.  But, I felt like i'd achieved something, I was knackered and there was cold beer in the fridge.

Getting the engine prepped ready for putting back in would only take a few hours right?
RS4Jules

Great work mate,glad day 3 was an improvement over 2    

Really good write up also,i just wish i could do all this with mine but damn
i hate all this computer stuff  
Odd replies and finding bargains on ebay is about my limit  
BHZ661

Fantastic work , and real good propress day 3  
Noggymike

ScottR wrote:
DAY 3

 It was time for a much needed brew.




I was now calm, collected and buzzing my tits off on caffeine.  




Just the 1 cup Scott?
ScottR

It was one of many required to maintain my blistering pace.
jimbo

you still got the same number scott ?  
FalleN

Nice progress over here That heat shield is really f*cked yeah. Mine is rusty on the other side haha, bay looks much better now that it's clean!
ScottR

I really can't understand how the two heatshields look so different when presumably they are made out of exactly the same metal.
ScottR

DAY4 and DAY5 (I started getting even slower!)

I'm going to give you 2 days for the price of one now.  Looking through the photos, I seem to have done virtually feck all on Day 4, despite my photos documenting 8 hours of activity.  I can only imagine I must have been doing some of my famed faffing, enjoying the sunshine and quite possibly being really hungover from the Engine Pull Celebration Party I had to myself after achieving a milestone on Day 3.  
 
And for some reason, i've only taken 2 photos the following day! (think there was a lot of cleaning, painting and watching the drying of the aforementioned...)

First task for the day was splitting the gearbox.  Nothing exciting to report here - it's a few bolts.


After being inspired by Plumb's sump cleaning skills, I had a go myself.  Still looks like crap compared to his, despite a lot of Gunk and scrubbing with a wire brush.  And don't get me started on how crap it looks compared to Fullraceken's super shiny sump!


This cleaning of everything whilst it was all out became a recurring theme.  I refuse to even think how many hours were invested/wasted in the cleaning of parts throughout this project.  Suffice to say, it would have cost hundreds if I was paying a garage to do it!

One of the jobs I had to tackle was a leaking rocker cover gasket.  Both in fact.  I also noticed what appeared to be leaking from the oil filler cap area.  :-s


Rocker covers were off, and not looking particularly lovely.  Cue lots more time-consuming cleaning!


Oh, and my not so delicate removal of the spider hose from one of the covers resulted in this.


I had planned to replace the spider hose anyway, but now I didn't have the option to do it at a later date if I ran out of time.


Cams inspected and all looking good.  



By now, you might have picked up on my recent discovery of my new favourite thing in the whole wide world... Hammertime!  

Sorry... Hammerite!

So guess what's going to happen next....


You guessed it...   more cleaning and prep of other parts ready for a good hammer(ite)ing!
Look at the freaking state of the front ARB!


The wire wheel was hardly touching some of the super cornflake rust, so I had to bump it up a notch and get the angle grinder out!


All this rust removal and painting with Hammerite was going to pay off though.  This next photo is what it is all about.  Just go back a few pages and look at the front subframe I had off Blue Thunder.  It was a little bit rusty, but not too bad considering it was off a 98 car.  Then look at how shocking the subframe from New Thunder was (below)!
Out with the old, in with the old but treated and repainted.  


Let's paint!



Whilst waiting for paint to dry (again), I removed the remaining bits of the spider hose.  
Yes, I would say this was definitely in need of replacement!  And believe it or not, I had attempted to get each connector off gently.


Ah... that will be the F-hose needing deleting too then!  Stupid brittle plastic!




I was now half way through my allotted time for the activity.  Let's see how i'm doing...

A very optimistic  ScottR wrote:

• Engine Pull = Work In Progress
• Fit K04's and pipework = Not started
• Fit RS4 Intercoolers = Not started
• Fit Injectors = Not started
• Fit Bosch 044 fuel pump = Not started
• Fit lovely new 'Liquorice Allsorts' Gearbox  = Not started
• Fit Downpipes = Not started
• F-Hose and N249 delete = No turning back now.... but Not started
• Fit new Rocker Cover Gaskets = Work In Progress
• Spark Plugs= Not started
• Replace front subframe = Work In Progress
• Replace rear arms = Not started
• Fit B5 RS4 brakes up front = Not started
• Fit Trig's B6 setup to the rear = Not started
• Fit Exhaust = Work In Progress
• Fit RS4 Oil Cooler= Not started
• Fit RS4 engine mounts + 034 Tranny mounts  + 034 Snub Mount = Work In Progress
• Replace front wings = Not started
• Replace steering wheel = Not started
• Fit cluster with repaired DIS = Half way there


It wasn't looking good for me.  Thankfully, I didn't have a Project Manager to answer to.   But in 5 days, I would have an angry Wifey, a sister and her fiancee visiting and a return to work meaning the car would need to take a back seat.  

FalleN

Good work though, clean bits are tits but it's getting boring when you've done a few and it's not even ending soon. Still cleaning parts myself ;(

Love the way you write, really entertaining to read!
ScottR

All I need now is mechanical expertise and your photography skills and I'd be the whole package!
FalleN

ScottR wrote:
All I need now is mechanical expertise and your photography skills and I'd be the whole package!


Would be an epic build right haha, give me your budget then
RS4Jules

FalleN wrote:
ScottR wrote:
All I need now is mechanical expertise and your photography skills and I'd be the whole package!


Would be an epic build right haha, give me your budget then


Only one thing for it  
You need another car for a joint build,Fallen you can do all the hard work and Scott you can be funny.
Sorted      
ScottR

We can do your next one for you Jules
Jakub

RS4Jules wrote:
FalleN wrote:
ScottR wrote:
All I need now is mechanical expertise and your photography skills and I'd be the whole package!


Would be an epic build right haha, give me your budget then


Only one thing for it  
You need another car for a joint build,Fallen you can do all the hard work and Scott you can be funny.
Sorted      


LOL!
FalleN

Haha, sounds like a plan. Should get my stuff together and move to the UK then
ScottR

Our first build will be converting your car to have the steering wheel on the correct side.
Noggymike

RS4Jules wrote:
FalleN wrote:
ScottR wrote:
All I need now is mechanical expertise and your photography skills and I'd be the whole package!


Would be an epic build right haha, give me your budget then


Only one thing for it  
You need another car for a joint build,Fallen you can do all the hard work and Scott you can be funny.
Sorted
     



Where do I sign up for that "Dream Team"
ScottR

Your in Mike!  You can do fitness.
Noggymike

ScottR wrote:
Your in Mike!  You can do fitness.


I'm not getting into my lycra gear anywhere near you!
FalleN

ScottR wrote:
Our first build will be converting your car to have the steering wheel on the correct side.


Hahaha, why convert something that was right in the first place?
I mean, you know your steering wheel is on the wrong side, have you seen your engine loom, they've extended it to make it fit. At Audi they were like, meh just extend it, not going to put that much effort in making it neat for those guys.   jk.
ScottR

DAY6

And finally, on to the most productive day of the build thus far.  The fabled Day 6.  Disappointed with my half arsed efforts on the previous days, and fast becoming aware that my deadline was approaching, I knew I had to shift it up a gear.  I was out of bed, fed and caffeinated all before 9:00.  A rarity.

With my breakfast well on its way to digestion, I started the morning with the pretty disgusting task of building a spider hose replacement.   The limbs of the spider were effectively just shattering.  Each time you would get a small sprinkling of horrendous smelling emulsified oil flakes.  All I could think about at this point was those school lessons where they showed you photos of cancer ridden lungs to stop you smoking. (oh - the staining on the wood was permanent!)


Like a tit, I hadn't bothered to put on any gloves for this bit.  I hadn't appreciated how messy it was going to get.  The black sludge which got onto my fingers made them smell like i'd been steeping them in overflowing ashtrays overnight.  The smell didn't wash off either.  Gross.
But, the job was nearly done.  One last unwelcomed surprise was the nipple on the top of spider body snapping clean off.  This is for the pipe which goes to the N75.  Could have done without that!


I didn't bother with rebuilding the spider at this point, i'd do this later when it was 'on' the engine.  So instead I took to removing the masking from the rocker covers and admiring my handywork.  


However, I had been a fool.  Why was I only taking this off now when I had these painted 2 days earlier?  I tell you why.  And this also explains why I got so little done over the past couple of days.  I wasn't happy with parts of the covers, as you could see the brush marks.  So I decided yesterday to use some wet and dry to try to even them up.  Being impatient is not a good trait to have in the paint world.  After being disappointed with progress after probably a few minutes of very gentle action with some high grit wet&dry with loads of soapy water, I decided to up the ante with some courser grit, and obviously hadn't bothered to wait to allow the paper to soften in the water.  Now, one of the problems with wet sanding is that the liquid takes on the colour of the paint.  What you should do is to regularly wipe away the excess so you can see what you are sanding, to ensure even smoothness.  Or you can do what I did.  A minute or so of vigorous elbow twitching with too much pressure (which from behind could have looked like I was a practising mechophile), and only after all that did I bother to rinse down the area.  Bo***cks...  I had gone through to the metal (and also not smoothed off some areas).  So I then had to prep and paint again.  Although this time I was much more careful not to overload the paint as I didn't want to leave brush strokes.  As time was running out, I had applied a few thin coats, thinking they had all sufficiently dried in between.  Then yesterday, I gave the covers some coats of clear High Temp Engine lacquer.  Only at this point was it obvious that the Hammer**ite hadn't fully cured.  It started to wrinkle underneath the lacquer.  Oh... and the lovely Noggy-esque colour started to change to a less lovely colour.

This photo shows the wrinkling quite clearly - and you can still see brush strokes. I would have been better off leaving it!  


Arse!  unfortunately time had run out.  I had no option but to fit them to stay on track with getting the car back together in the next few days.

Everything was cleaned carefully to remove any traces of the old sealant, I had to (very carefully) use a razor blade to get some of it off.  Then a wipe with some brake cleaner and it was ready for new sealant and new gaskets.


First side done, and it was time for new spark plugs.  I wanted a fit and forget solution, so forked out for a set of NGK BKR7EIX (the Iridium version of their popular platinum plugs - supposed to be the same quality cool spark with better longevity).


And the coils fitted.  Rocker cover uglyness starting to show.  



At this point, I thought it was fairly safe to assume my rocker cover gasket replacement would solve the burnt oil smell that used to fill the car all the time...


Next job was to remove those piddly little kazoos!  I also have ported and tig welded manifolds to go on, so it was easy enough to just take everything off together.  Only unpleasant bit here was seeing more of that disgusting coolant when I disconnected the turbo coolant banjos:


But on with the progress!


As mentioned, at least one of these K03's had been making a faint dentist drill noise for a long time.  Maybe even a year.  Since the day I started this pull, I had managed to make one get much louder! (I absolutely hammered the car to Bradford and back to see if the turbos would stand up to it! )
So I was expecting to see a badly deformed compressor, lots of shaft play, obvious signs of the blade hitting the housing....   In fact, the only thing which hinted at the fact that these turbos were on their last legs was a small deformation on one of the blades and some 'dusting'.  No shaft play at all.  


And now for the money shot...  baby tiddler K03 next to its bigger (and considerably less travelled - by about 110k miles) brother!


Now another reason for me taking off the turbos and manifolds in one piece before is that I had done the same when dismantling the old car.  So made life much easier.  I'd forgotten how fiddly it can be to get the oil/water lines onto the turbos though.

One trick I did remember was to loosen the pass side turbo from the manifold a bit in order to get to the coolant line.


And another was to use a small 6mm hex bit and a 10mm ring spanner to get to the awkward manifold bolt closest to the head:


At some point along the way, I also realised i'd lost the clip which locks the hydraulic line into the slave cylinder.  Had forgotten to mention that during the battle of man vs slave cylinder when I was pulling the engine, that after over an hour of huffing and puffing failing miserably to remove it from the gearbox, I lost my rag, pulled this clip and decided i'd just pull the clutch line out and deal with the nightmare of bleeding it at a later date... but then I couldn't even manage to pull the clutch line out!    That was the point when Stigter arrived and I took an overdue break.  As you may remember, I was able to detach the slave from the gearbox in the end without disturbing the clutch line.  Anyway, back to now.  So I realised the clip was missing.  I looked everywhere for it, but it had just disappeared.  I didn't want to forget about this, so I put a zip tie around the slave so i'd remember to go back to it before putting the engine back in.  A short while later, I found an answer.  It was to be one of my greatest ghetto bodges of all time.  I found a small nail.  The very small ones you use to fit the back boards to shoddy flat pack furniture.  It was the perfect width!  I was able to bend this into a horseshoe shape, then using some mole grips was able to press it into the slot where the clip usually goes.  It's in there perfectly tight and there is no danger of it shaking loose.


Back to the main story.  Have a blurry photo of one side done:


No... have two!


One side down.  It had taken 3 hours.  Much slower than I would have liked, but at least the next side should be much quicker.  Emphasis on the should.


It was at this point that I remembered one side being particularly more fiddly to deal with than the other.  And i'd also begun to realise, it was this side!  Obviously getting the manifold on this side was no different.  But it is a pain in the ass job.  There are quite a few nuts holding the manifold on, and they aren't your common or garden nuts, oh no.  They are some sort of wacky elliptical hole nuts, so they 'pinch' on the thread.  Now I come to think of it, these are very possibly called pinch nuts (yes - google seems to have just confirmed this for me).  So it's a battle to get these on/off.  You need wrists like Popeye when Olive Oil is out of town.  

Anyway, the problem lies with one of the banjos in particular.  They are all awkward, don't for a second think this is going to be easy.  People who say they have fitted these turbos whilst the engine is in-situ must have used Jedi powers.  

Here's a pic of the particular bas***d banjo.


It doesn't look too bad from that photo, but what you can't really get a feel for is how small this is in real life (unless you are viewing this on your phone, in which case, it's probably a bit bigger than you think).  The gap between the two banjos is a cigarette paper's width.  You can just about get the tips of a normal spanner on there, but then you manage about a 4 degree turn before you are stuck.  The spanner handle hits the hotside of the turbo, which also limits how much turn you get on each attempt.  So, let's try it with a socket from above...  

Fiddlesticks! (and just look at the horrible dirty hardlines too... yuk!)


If only there was some way of getting that hardline out of the way (the one held in place by the bracket circled in green above).  I had a cunning plan.  I'd simply undo the bracket, move the pipe, then tighten the banjo with a socket and reattach the bracket.  Oh wait... the bracket bolt hits the banjo when you try to undo it.  I was tired and getting pissed off (a pattern doth emerge...).  It was time to break out the bodger's essential piece of kit - the Dremmel!
Now don't judge me here people.  I have skimmed over it in this light hearted tale, but I honestly believe I had spent more than an hour to this point trying to figure out how to do up this one banjo.  

The bracket must die!  I covered the line so it wouldn't get any swarf in, and also used a soldering mat so nothing got near the turbo blades.


A couple of minutes later....  Ta da!!!   (and note what a sad bugger I am, having  cleaned all the hard lines whilst I was in there )


Would love to know how others do up this banjo.  I don't remember having a problem with it previously.  Should I have done this one first before the one next to it?  

Anyway, it was done!

And I was done.  

It was 21:00.  A 12 hour marathon!  A truly epic day of getting a few hours work crammed into 12 hours of swearing and awkward bolts.  I have more sympathy for garages charging 'book time' when they've actually completed the work on a car in half the time, because now and again, they will hit something awkward like this.
jockthedog

Could you get a ratchet spanner over the banjo bolt maybe?
ScottR

Now you mention it...

ScottR

Nah, not a chance in hell of a ratchet spanner due to the tiny gap between bolts. Possibly a cheapy ring spanner though.
torque2me

I lost my slave cylinder clip today swell. Anyone show me what it looks like?
ScottR

Looks like an Ikea nail bent into a horseshoe shape!
torque2me

I might try your trick. You sure it ain't coming out.
buzzard

Great project Scott
It's great to see a grass roots build on a good ole B5
Is that my old ecu by the way??( rick took the ko4 ecu off my old machine to fit his own spec system.....
Just curious.
ScottR

DAY7

After yesterday's marathon session, the engine was nearing the point it could be put back in.  Just one final push...

First job of the day was fitting the new fancy 5 puck clutch i'd bought.  This bad boy would stand up to K04 power, and more importantly flat shifting.  The last time I had fitted a clutch, i'd done it by eye.  This time was no different.  Bodged up an 'alignment tool' out of an old highlighter and some thick tape.

Smart eh?


I know some of you will be taking the piss, but I think this is not bad!


Carefully tightened the clutch bolts in sequence and finally torqued them up to spec.  I wasn't wanting to mess this bit up.  The last thing in the world I wanted was for the engine to need to come out again!

After getting that sorted, something caught my eye.  Remember earlier when I had noticed the completely rusted heatshield?  No time like the present to sort it out!  I wanted everything ready for the engine going back in later than day.  I was scavenging round trying to find what I had which I could use to make up a replacement, as I obviously hadn't noticed the issue until a few days earlier when the engine was out, and I was expecting it all back in many days ago!  

Managed to find some galvanised lawn edging.  Yes, it was going to be one of those bodges!


A bit of cutting with the snips, a brief file of the razor sharp edges to reduce the chance of cutting off my arm, and some 'delicate' shaping with pliers and a hammer and....



Could have been worse!  It wasn't going to rust too badly, it was the right shape and most importantly it was going to offer more shielding of heat than the piece of rust I took off!  Wasted over half an hour searching and making the thing though.

Gearbox time!  Used the tried and tested approach of putting the gearbox on a box, hoisting the engine up to the right height (takes quite a bit of doing if you don't have a second set of eyes to assist here) and straddling the box before pulling the engine onto it.  This was the second time in as many days that I looked from behind like I was getting jiggy with car parts!  
I usually get it so you can feel it slide on, then put in a couple of the longest bolts first, then it's easy to wiggle it fully in before putting in the rest of the bolts.


Once fitted, I had one last job to do which would be easier before the box was in.  I had to make up my spider hose replacement.  Measured up the hoses, cut them, fitted them and only then remembered I had to deal with the broken nipple on the top.  Arse!  Decided to just cap the top, as I remember reading that this hose from the N75 effectively just vents and can vent to atmosphere without issue.  I ran a bead of black silicone around the top of the spiderhose, then cut a piece of old arch liner to shape and stuck this on the top.   Genius idea.
However I accidentally touched the bloody thing before it had cured and it slipped off, making a mess.  


Plan B....  I found a small bolt just the right size to fill the hole.  Put a tiny bit of silicone on the thread to ensure a seal, screwed in the bolt to the hole at the top, then covered the whole thing in silicone making it resemble a black walnut whip.  Tasty.  Sadly it seems I wasn't proud enough of my ghetto bodge to take another photo.  I'm guessing my hands were probably covered in sticky black silicone and I didn't want to feck up my phone.  But, I wanted to leave it time to dry a bit, as I didn't fancy anything falling off again whilst putting the engine back in.  Got the downpipes fitted with new gaskets and attached to the gearbox.  I was making good progress.

I stopped for a well earned brew, and took a moment to stand back and admire my handywork from earlier in the day.  That fuel line heatshield was a bodge too far!  Even by my standards, that was poor.  I started a hunt for something better.  Where was I going to find some suitable heatshield material???

Oh yes, forgot about these....  I had a perfectly good turbo heatshield from the K03's!  (I also had one completely fu**ed up one as I couldn't get it off when trying to remove the downpipes the other day(more time wasted!), so went apeshit with some tin snips and eventually the angle grinder!
I marked up the good one using the rusty cornflake as a template and cut it out.


But, it's size and shape were actually not bad at all.  Half an hour later I was much happier with the finished product than my previous bodge.  Looks factory!  (Lada factory)


The time was 18:21.  It was time.  One last look at this lump and beautifully painted gearbox before it went back home, I'd probably never see this sight again.  I never wanted to see this sight again!


This would be the 3rd time I had put an engine back in myself.  I wasn't worried.  But I knew the weather was due to take a turn for the worse the next day, and I also knew that if the engine wasn't in before the morning, that would be half the morning wasted doing it then.  It had to go in now, and it had to go in right.  Dinner and rest would have to wait!

My car mad neighbour came over to see how things were going.  Bad timing Neighbour... now you've got to help!    Manouvering the crane as well as a trolley jack underneath the gearbox is possible on your own, but it's a real bloody faff.  I was very glad of the extra pair of hands.  From those of you who read Project Thunder, you might remember my neighbour Tom helping me get the engine in that time as well.  He still blames himself for the crane/bonnet interface that occurred that time!    

A painful reminder, but a valuable lesson learned!


However it had been my fault for having the chains too long onto the engine, so lesson learned, this time I had hooked up the chains much shorter.  This would give us more clearance, but I find it more fiddly because you can't get as much 'swing' to manoeuvre the engine.  There would be no danger of hitting the bonnet.  We were both on Red Alert for that!  
After not too much time, we had everything where we wanted it.  Just the small matter of re-engaging the clutch slave, and it would be ready for the final fit.  Only it's never a small matter with this 'orrible little twunt!  Cue nearly 2 hours of swearing (documented here)...  But, I finally got the better of the little b*stard with a combination of brute force and sheer rage.


It was after 22:30.  What a day!
Kent

haha oh good. glad its not just me. did exactly the same on my bonnet. took me ages to realise why the engine was just not going in.

Mines just a few scratches tho. Looks like you were going at yours with the force of ten elephants
ScottR

I go from calm and methodical to full hulk within a few minutes if stuff isn't working for me!
Kent

id pay to watch you 'full hulk'
RS4Jules

Massive credit mate,fantastic work  
ScottR

Forgot to mention that even after the slave was dealt with, I had a nightmare of a time trying to get the heater matrix hoses back through the gromit in the firewall. Don't remember this being an issue in the past. This time around it was a real fight. Probably because it was dark, it was hours passed my dinnertime (and rapidly approaching bedtime!) and I knew I'd have to get this sorted before I could drop the engine on it's mounts or it would have to come out again in the morning in order to sort the pipes then. I think my initial problem was maybe having the pipes on the wrong side of the power steering hose, but as I was working blind I'm not too sure. Pretty sure this is how James Herriot felt when he used to don his shoulder length rubber gloves!

In the end I just pulled the grommit out of the way and forced the pipes up by fair means or foul. I was getting desperate by that point. I shed a tear of joy when the hoses emerged through the firewall, it was like seeing my first child born, without the trauma of seeing my wife being ripped to shreds. (I imagine).

Once the pipes were through, dropping the mounts in place was straight forward. Would have been easier with two sets of eyes, but doable yourself. Just involves lots of getting under the car to see how close the mounts are, getting back up top to adjust the engine/crane/jack and repeat...

Was so happy to unclip that engine hoist I can tell you!
david1980

how's the 10 day list going now? should be a few more bits ticked off
Noggymike

Have you ever been on Scrapheap challenge Scott?
ScottR

I live on the scrapheap Mike. I can build anything out of anything... so long as it isn't a 2.7T Audi!
torque2me

Well done mate. I achieved mine the weekend too so that pain is still fresh for me. I dropped mine in only to then realise the prop wasn't perfectly aligned and the shifter rod had popped down.

What did you do with the heater matrix hoses? I didn't touch these....
Only hoses at the rear i touched were the coolant hoses with the push fit clip.
FalleN

Great job, again! Fantastic reading material haha, everything sounds so familiar!
ScottR

torque2me wrote:
What did you do with the heater matrix hoses? I didn't touch these....
Only hoses at the rear i touched were the coolant hoses with the push fit clip.


The first time I did an engine pull I unclipped these hoses from the gallery at the back of the engine.  Did a track day a few weeks afterwards and one of them popped off!  Also find them very fiddly to remove.

Since then i've just unclipped them from just underneath the windscreen and pulled them through the firewall.
ScottR

DAY8

After yesterday's troublesome day, I hoped today would be a breeze.  Surely only a few nuts, bolts and hoses left to connect up to get the car started.  Within minutes I had noticed my first problem.  Sigh....

In my rush to get the engine in the previous night, I had forgotten one of the noddy steps - get the shifter rods into the shifter housing.  They were now underneath the shifter housing, and it without putting the engine back on the hoist and lifting it free of the mounts, it was not going to be possible to move the rods back far enough to get them in.

You can see here, the accordion boot which should go into the shifter tub is sitting below it, with the shifter rods sticking a few inches underneath.


A massive inconvenience, but I was planning on fitting my short shifter at some point, just thought it was going to happen a few weeks/months after the car was all back together.  I decided to look at this problem as an opportunity.  I really was fishing for positives at this point!
I realised I could move the Prop far enough out of the way to drop the complete shifter assembly tub out.  As I had taken the short shifter out of the old car in this way, it would be a simple case of just fitting this instead and i'd only have 4 bolts to deal with.

Managing to get the shifter tub out passed the prop (note: I did have the CV's all covered with bags to stop crap getting into the grease - i'd only taken these off when I noticed the damn shift linkage!)  And damn... I was going to have to give these heat shields a clean.  


Problem was solved!  Next task was to refit the prop and driveshafts to the box.  As this was newly refurbed and I'd cleaned the flanges, I needed to put some grease in.  What I hadn't realised was that the grease cartridges were not like a typical bathroom sealant style cartridge with a 'base', and I didn't have a grease gun.  Time for another bodge....
Thick plastic sheeting over very large socket to the rescue - this was going to get messy!


It worked fairly well.  Although I was pretty much covered in the stuff by the time i'd done all 3 flanges!

I was very careful to ensure that the grease didn't get into the thread holes.  I did not want a repeat performance of a driveshaft coming off at speed again!  Red Loctite was applied liberally on the 18 driveshaft/propshaft bolts and torqued up nicely.  

When I went inside for lunch, thought i'd spent a few minutes doing the 'Darintake mod'.  I didn't want to just cut the front out completely, so just drilled a few holes and ran a countersink through them to clean them up (then worried that the angled edge which resulted would act like a load of whistles... thankfully they did not! )  Note - I wasn't doing the drilling with the new filter in place!!


After lunch I got the aircon compressor back in place.  For some reason I had real problems getting some of the bolts going.  They can be bloody fiddly, especially the hidden one at the back.  How can these things weigh so damn much?

As i'd snapped the plastic joiner which the F-hose went into, the F-hose delete was no longer a nice to have option, it was a necessity .  I'd priced up the 'proper parts' from Audi and it was disgusting how much they wanted for a few small bits of hose.  I found the reason why is that the 90 degree angled hose which replaces the F-hose has a different diameter at each end.  I searched for ages to find a cheaper alternative, but in the end ran out of time and patience.  I had also wasted a morning earlier in the build driving around Liverpool to various hose places trying to get the various pipes, joints and fittings, but which very little success.  One place had ordered fittings in the right size... for copper piping.  Arse!!!  Last place I tried was a local motor factors.  They had a big box of loose hose joiners of various sizes/angles and a variety of different hoses.  I bought a shit load for buttons and thought i'd see how I got on.  The result made me think of a classic Viz sketch - "Frankenstein's Cock".


Unfortunately i didn't write down the fixtures, but think it was (from right to left on the pic) 1/2" hose out of the manifold, 90 degree 1/2 joint, 1/2" hose out, 1/2"(12-13mm)-5/16"(8mm) reducer and finally some 8mm fuel hose which goes to the one-way valve.  As you can see, as a bonus bodge to stop the hose at the left from collapsing, I put another worm clip around it so it holds shape.  Remarkably this ugly set up works!  If I ever find any inspiration to have another go, i'd probably try to find a 90 degree 1/2"-5/16" (13mm-8mm) elbow reducer and a 90 degree 8mm elbow joint.  However i've no idea where to look for the reducer elbow.  Any suggestions?

A nearly new aux belt tensioner fitted from the old car, and some lovely hammerite to make the pulleys pretty again.


Nearly new coolant reservoir fitted, airbox fitted, belt on, cleaned and repainted coolant hardlines on, fuel lines and all engine electrics refitted and put in place, Y-pipe, etc.  It was finally beginning to take shape.


Nearly 7 hours done today, and to look at, very little to show for it.  Looking back, I must have had some nightmare issues with it which i've simply blocked out of my brain for fear of getting PTSD.  But there surely couldn't be much more left to do to get it driving now.  In my mind, there was a quick 5 point plan:

Fit Intercoolers
Fit Oil Cooler Sandwich Plate
Whack front end on (w. Oil Cooler)
Fill it up with fluids
Fire up the Quattro!

What do we reckon guys?  Will it be as easy as that?  Tune in next time for more fails, problems, slow progress and torrential rain (probably should have done a bit more today when I saw the weather forecast for tomorrow...)
armageddon

I'm interested for the next chapter(fitting intercooler) my rs4 intercoolers installation did not end quite well
BHZ661

Lets hiope its all plain sailing with the last jobs  
ScottR

BHZ661 wrote:
Lets hiope its all plain sailing with the last jobs  


Spoiler alert... It's never plain sailing!
BHZ661

Well perhaps a little drama so we can read about it on  the next update of thread  
ScottR

Exactly! This would be a very boring thread if I was a skilled mechanic.

Updates coming soon.
bboy82

Outstanding work fella! I've been stuck at the 'it's nearly ready to fire up' stage with Plumb's build for 2 months...!.
ScottR

DAY9

The penultimate day before wifey got home, I was so close.  But, what should have started off as a small series of easy tasks, started immediately with problem number 1.  I was just getting ready to fit my intercoolers, driver's side first.  

What's this?  The intercooler hose isn't reaching the alloy pipe, and not a small gap either!!



1000 red asses!!!!   I had refitted the S4 hose on this side instead of the RS4 hose.  And as you can see from the photo above, there was a lot of crap in the vicinity which made this a really fiddly job.  Think I had to loosen off the starter motor.

But once off and next to the correct hose, it became clear that I had indeed been a fool!


The RS4 intercoolers require some cutting of the inner wing support and also the inside of the bumper (ie: the support bits).  I found cutting the bumper terrifying, as one small sneeze whilst using a power cutting tool would result in the 'skin' being pierced.  I had to use a combination of Dremmel cutting wheels, an angle grinder for the deeper bits which needed cutting, pry bars and mole grips.  Was not a lot of fun, I can tell you!

So on my old car, the passenger side wing and bumper always had a large gap between them since the RS4 intercoolers were fitted, and that was using the proper RS4 intercooler mounts (which I hadn't realised, and let them get taken away to the scrapyard with the shell! ).  So I wanted to ensure the intercooler sat as high up as I could get away with.  i realised that the S4 mounts must sit slightly higher up than the RS4 mounts, and with a bit of rough measuring figured I could actually fit the intercoolers underneath the S4 mounts.   I had heard of the yanks just letting the IC's dangle, but I didn't like the idea of them bouncing about over rough ground and didn't want to risk anything piercing the core, so I used Jubilee style clips to attach them to the S4 mounts.

This held them nice and firmly and they appeared to be in the right place.



The lower mount was causing the coolers to stick out at the bottom, so I got cutting...




On the drivers side, it was a little more involved.  The lower mount I was able to just 'adjust' with the might of Thor, but the top of the aircon drier and the 3rd bolt holding it in place was getting in the way of the intercooler.  It was time to call in the big guns... angle grinding time.  But I wanted to ensure I wasn't going to get any swarf inside the bipipes, so the remnants of last night's celebrations came in handy....


Once that was cut, the drivers side intercooler just sat in place nicely.  Next job to tackle was to fit the RS4 oil cooler.  On my blue car (which was PFL), I didn't really have any major issues with fitting the oil cooler, but New Thunder wasn't having any of it!

It was quite the puzzle...  You can see here that the oil takeoffs were in the way of the coolant hardlines.



I tried moving things around, using different rubber hoses, even tried using a pipe bending snake thingy, but these steel pipes were just not wanting to move!  I must have wasted easily over an hour trying different things, but it just wasn't happening.  Ever aware of my fast approaching deadline, this was going to have to be a job for another day...

Got the 034 snub mount fitted to the front panel (that was a ballache due to most of the stupid captive nuts snapping clean off), removed the oil cooler and got it all fitted.  I used a shedload of rubber grease on the snub mount to get it in.  When in doubt, get the lube out!

I'd only just about got eveything back on and in place when this happened...  rain stopped play!


Once i'd finished getting my annual wash, I went to fit the front brakes.  Wasn't going to have time to do the rears, but thought i'd get the fronts sorted.  As you can see from the pic below, I just knew this wasn't going to want to happen without a fight.


I was getting tired and not in the mood for annoying hinderances.   A rusty bolt holding on the heatshield decided to test my patience...  it was approximately 8 seconds before I reached for the angle grinder.  I really should put this in a secure box so that I can only access it when I am in a fit state of clear headedness to use.   I'll look into inventing a 'red-mist-o-meter' which prevents use of such things when in a state of uncontrollable rage!  

Take that you b*stard!


I called it a day after an 8 hour slog.  It was nice to see it looking almost like a car again.  Don't worry... tools were all cleared up before shutting up shop for the day!


I was soaked through, covered in oil, dust from various grinding action and mud from crawling under the car all day.  I'll bet wifey couldn't wait to get back home to this hunk! (me)
Noggymike

ScottR wrote:

 I'll bet wifey couldn't wait to get back home to this hunk!



Me neither!

IchBautAuto

Rugby colours

Nice jumper, good to see you waving the flag.
Noggymike

Re: Rugby colours

IchBautAuto wrote:
Nice jumper, good to see you waving the flag.



Scotcoub

Loving the write up, I'm planing to pull my engine very soon to do the clutch flywheel and send my k03s away to to be reconditioned as well as tidying up the bay cleaning and paint a few bits 👍👍
ScottR

Re: Rugby colours

IchBautAuto wrote:
Nice jumper, good to see you waving the flag.


Thought it would be appropriate given the amount of time I was down under the car...


Ba-boom-tish!
Noggymike

Re: Rugby colours

ScottR wrote:
IchBautAuto wrote:
Nice jumper, good to see you waving the flag.


Thought it would be appropriate given the amount of time I was down under the car...


Ba-boom-tish!



















ScottR

DAY10 - The Awakening!

The day of reckoning had arrived.  Only had a few minor things to see to before I could fire it up and drive!

Started early with some front Brake action.  B5 RS4 setup, lovingly painted in blue and fitted with brand new braided lines.  Not many pics from this point forwards... I didn't want to waste vital seconds of the build...

Oh, also replaced the grubby looking brake fluid reservoir.


Wasn't particularly happy with the orientation of the braided brake line, so ziptied it to the upright as a temporary measure to ensure it didn't touch the rim.


And the finished result...  (note the correct fitment of the spring retainers!)


I only bled the front brakes as I planned to do the rears soon after.  I bought a Gunson Eezi-bleed and was so glad I had.  It really made bleeding the brakes a piece of piss!

Another photo of the engine all back together and in place.  Rocker covers look pretty good here I think.  And the new coolant reservoir looks much nicer!



All fluids in, new DIS fitted, all pipework and electrical connectors checked over by eye... battery connected...

Fired up the Quattro!

Hadn't bothered fitting the exhaust as I was just wanting to see that it would start.  It did.  Hastily attached the exhaust, then fired it up again and let it run up to temperature.  At this point I heard a horrible screeching noise... same as I do every time I do this, but always forget.  The PAS pump needs you to turn lock to lock a good few times to get the fluid around the system.  Once i'd done that, it sounded beautiful again.  

There was one issue though, the main fan was going off it's tits, probably providing enough thrust to move the car without the engine!    I'd forgotten to mention earlier in the thread, but when I was initially fitting the front panel, I managed to pinch the fan wires underneath the bumper support (all of the clips which hold these cables usually rust away to nothing.  It was a small disappointment, but not the end of the world.  Disconnecting the large red connector behind the headlight stops the fans.  I could deal with that after the test drive.

When the coolant was up to temp, a final check underneath the car for leaks.  Happy to report there wasn't so much as a drop anywhere.  Onwards!!

Front Bumper on!


And I was pretty happy with the panel gap between the bumper and wing.  This was far better than anyone I'd paid to fit on my Blue car had managed!


Unfortunately....  the drivers side (which incidentally was never a problem on the blue car) now had a gap (although was fitting flush with the wing).  


Grrrr....    No time to fanny about fitting that, I wanted to drive the thing!

Dropped the car onto 4 wheels, checked all the wheel bolts again, engine cranked.  It was the moment i'd been waiting for.  So off to do a lap of the block.  Before I set off, I remembered the first time I drove my old car after my first ever engine pull... and the terror which set in when I first pressed the brakes and nothing happened!    Remembered to pump the brakes up this time!  

Start off up the road slowly, everything seems good.   Literally after about 10 metres I check my rear view mirror.  That's odd!  There appears to be a thin line of fluid on the road exactly where I have driven.  Surely a coincidence?  I did a little chicane manoeuvre...  and guess what I then saw in my rear view mirror!  Yep, I was leaking!

Jumped out of the car, looked underneath and there was a thin trickle of fluid coming from the drivers side of the radiator.  What the devil could it be?  Did a 3 point turn and returned the 20metres back to the house.  Surely I must win an award for the world's shortest road test??

Any guesses?


Another clue...


Got the car jacked up so I could take a proper look.  



Got the answer yet????







That's right...  I'm a tit!!!

In my rush to get it going, I hadn't tightened up the flexible gearbox oil cooler lines.  I thought I was being smart when running the car up to temperature on the stands to check for leaks, but what I hadn't figured on was that the gearbox only gets pumped round the system when the wheels are moving.  What a mistake-a to make-a!  

At £20 a litre, i'd have been as well off pouring a decent single malt down the drain!


I didn't have any more oil, so the test drive was put on hold for another day.  I was raging.  But not as raging as Wifey would be when she saw what 3 engine pulls have done to our driveway over the last couple of years...  


Day 10 ended in misery.  Really miserable misery.  A real shame, as other than the foolish failure to tighten 2 bolts, the K04 build had largely been a success.  But it had been at a cost.  I hated the car, I hated working on the car, I hated not being able to drive the car.  I hated everything!

But all I had left to do was tighten 2 bolts, buy another bottle or two of liquid gold and fit the fuel pump and I would have a sorted 400+bhp car.  Still had a few minor jobs to do:
Fit suspension
Fit rear brakes
Swap over steering wheels
A bit more cosmetic tarting up

But I wasn't far off.  There was light at the end of the tunnel.

At that moment I made a vow.  I would never do another engine pull again!

I'd have everything wrapped up over the next few weekends.  Surely?
bboy82

It's really coming together, don't give up now, we're all counting on you... And stop calling me Shirley!
FalleN

Awesome! And not the smartest thing about the oil cooler lines haha, but those things happen
ScottR

FalleN wrote:
Awesome! And not the smartest thing about the oil cooler lines haha, but those things happen


Thankfully the gearbox oil cooler lines. If it had been the actual oil cooler lines (ie: engine oil), I wouldn't have been so 'lucky'.
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