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reaper

Project S4 WB 1 of 3

Hi Everyone,
Been on SRS for ages and I thought it was about time to post up a build thread.

As those who've met me will already know, I'm building myself three S4 WB Saloons over the course of the next 12 to 18 months, one for my daily drive, one for the weekends and finally a full carbon fibre panelled track day car.

Each will get posted into it 's own thread, but here is number 1

The Daily Drive.

Bit of History

Bought the 99  S4 in Aluminium Silver off an eBAY auction back late November 2010.

As the car was based top side of Aberdeen, I took a chance on it and at first the omen's weren't good as the flight to collect it was cancelled due to heavy snow fall and I ended having the worlds worst journey on a National Express bus that struggled through all the snow to get us there.

Luckily, I was pleasantly surprised to find it wasn't a total donkey and apart from some rough old 18" RS4 Replicas, it was in standard specification. My mood also improved with the journey home as the car drove the 300 miles back perfectly and was a real laugh through all the white stuff!

Due to work, a couple of days past and I still couldn't bring myself to take photos of it initially as it looked crap with the wheels in such a badly corroded condition, so the RS4 Replicas were whipped off and replaced with some temporary RK5's to tidy things up.

The addition of a new headlight washer cover to replace the one that was hanging off, left me with the car looking like this. (Minus the RS4 grill)



Then the brown stuff hit the fan at home when the wife got diagnosed with cancer so everything went on hold and I ran the car for a little over 6 months until the MOT expired.

As I hadn't looked at the car since purchase, I foolishly popped it to a m8's for MOT only to find that although the body of the car was solid, there were some major issues that requiring a shed load of work for it to pass the MOT!!

With no time on my part due to the issues at home, I Sorn'd it off and it sat on the drive for months until I finally drove it to my unit where it lay until August 2012 when the wife finally got the all clear!

That's the boring introduction bit over, will post up the plans for the car, spec and progress over the next few days
ScottR

What a greedy bugger!  And we all thought Ash was bad with his two!

Look forward to seeing the progress.
reaper

ScottR wrote:
What a greedy bugger!  And we all thought Ash was bad with his two!

Look forward to seeing the progress.


What can I say, it's just got to be done

Pretty easy decision for me after the nightmare problems I've had with my last B6 and the B7 so it just made sense to throw the cash at some good looking B5's rather than buy new
tino

Subscribed !
pjbRs

3wb's wtf?  That's going to Be a rare collection.

Hope your mrs is ok.
reaper

Before I decided on the exact spec etc, order of the day was to get it back on the road and having been parked up for an age a full oil service was done.

At the time I still needed to be home with the wife during her recovery, so I had the S4 dumped back on the drive and work began on an axle stand special getting it ready for MOT.

Job number 1 was to deal with the front end, so up on axle stands and off with the knackered front brakes, control arms etc.

As normal first up were the dreaded pinch bolts, but the application of some heat and Mr Hammer soon had them sorted!


Followed by the removal of those nice front brakes


Next the upper and lower control arms


Leaving me with the car on the drive looking like this...


Just when I thought it couldn't get any worse, I inspected the heavily rusted front subframe and pushed my finger straight through it!

Looks like it's time in the Scottish sea air had taken it's toll, so off with the subframe and it really was this bad all over!
Tony K

I have a decent rot free subframe if needed?
colinurquhart

Looking forward to these 3 threads, love a good story.
reaper

pjbRs wrote:
3wb's wtf?  That's going to Be a rare collection.

Hope your mrs is ok.


I'm really looking forward to the finished cars and probably more to all the work on them!

The plan was initially to have just two, but I did a large kitchen extension for a m8 who got made redundant and did him a solid by taking his tatty old Noggy S4 to cover the 5.5k he owed, hence I ended up with 3 donor cars

Mrs is getting there thanks, she just needs to keep clear of drunk drivers at all will be good
reaper

Tony K wrote:
I have a decent rot free subframe if needed?


Cheers for the offer Tony!!

I had a spare lying around at the time and since then I've picked up a couple from an RS4 off Jimbo!
reaper

I've done a load of Cayenne brake conversions and had a spare full set of front 17z's and matching rears lying around, so I decided to fit them for MOT.

Ordered up new cross over pipes, bleed nipples, pads, seals, retainer bolts and springs form Porsche and set about refurbishing them.

Picture of a rear from the set prior to refurb


And a front after bead blasting, high temp coating and decals


For those interested and despite the fact that the brakes are temporary and promised to a forum member, I will be posting up the full rear Brembo conversion including handbrake callipers later in this build.
Ash25

reaper wrote:
ScottR wrote:
What a greedy bugger!  And we all thought Ash was bad with his two!

Look forward to seeing the progress.


What can I say, it's just got to be done

Pretty easy decision for me after the nightmare problems I've had with my last B6 and the B7 so it just made sense to throw the cash at some good looking B5's rather than buy new


Haha yeah I thought I was being greedy with mine   but I'm with reaper on this, throw some cash on some good looking B5's I reckon!   Off topic, how's yours going scott? You need to update your thread with some details....

Sorry to hear about your wife's problems reaper, hope she is on the mend and recovering ok etc.

Looking forward to the 3 WB builds, should be good. Surely the weekend car will be the trackday car though? Or are you going totally mental and doing a full-on stripped with cage/no chance it will get an MOT track car?

I think you can get the B5 to a state where the interior/exterior is just as nice and 'modern' as any new car, but of course it will probably only be 'worth' doing it if they are keepers, as I am sure these will be.

What level of modification/tune are you going to do for each car then, as many people use high power cars as dailies on here? Assume you will; be going for K04 minimum, or sticking with the K03 on the daily?

Keep the pics coming, will be an interesting set of builds. Top stuff!

Cheers

Ash
reaper

Ash25 wrote:
reaper wrote:
ScottR wrote:
What a greedy bugger!  And we all thought Ash was bad with his two!

Look forward to seeing the progress.


What can I say, it's just got to be done

Pretty easy decision for me after the nightmare problems I've had with my last B6 and the B7 so it just made sense to throw the cash at some good looking B5's rather than buy new


Haha yeah I thought I was being greedy with mine   but I'm with reaper on this, throw some cash on some good looking B5's I reckon!   Off topic, how's yours going scott? You need to update your thread with some details....

Sorry to hear about your wife's problems reaper, hope she is on the mend and recovering ok etc.

Looking forward to the 3 WB builds, should be good. Surely the weekend car will be the trackday car though? Or are you going totally mental and doing a full-on stripped with cage/no chance it will get an MOT track car?

I think you can get the B5 to a state where the interior/exterior is just as nice and 'modern' as any new car, but of course it will probably only be 'worth' doing it if they are keepers, as I am sure these will be.

What level of modification/tune are you going to do for each car then, as many people use high power cars as dailies on here? Assume you will; be going for K04 minimum, or sticking with the K03 on the daily?

Keep the pics coming, will be an interesting set of builds. Top stuff!

Cheers

Ash


Hi Ash,
Will post up the full spec on each as the builds progress, but I can guarantee you they will all be on decent power and running modified K04's as a minimum.

However, the weekend car is just that and will be going no where near a track

Without giving to much away, I will confirm the track car is going fully stripped and will be loaded with as many carbon panels as I can safely produce!

Cheers
Phil
Noggymike

Can't wait for the story to unfold
reaper

Quick picture of a few Cayenne parts from Porsche, including cross over covers for the rears


With the front callipers now re-furbed, I pressed a new set of bearings into the front hub carriers, masked off the bearings, bead blasted and re-coated in black.

My spare subframe followed the same treatment and once done it was replaced along with the inner and outer CV's, hub carriers, control arms, track rod ends and to finish a dry fit of the callipers



Before any one mentions the callipers are mounted upside down, read on  

They aren't .......

Wanted everything to look just right, so I built up the notch were the cross over pipe sits on the calliper with alloy weld, ground in a matching groove in the opposite edge, smoothed everything off and finally used a very fine shot blast to reinstate the texture on the newly formed parts before they where final coated
reaper

Next were the discs.

As this set up is being sold on I went for handed M-Techs to ensure correct heat dispersion, but used CLK 320 AMG drilled discs not ML's.

This particular disc only requires it's center bore opening 1mm and then it's a direct fit without modifications to the hub carrier or the calliper.

The only difference to the ML setup is the disc is offset by 1mm from the center line of the calliper, which you can see in the picture below  and has absolutely no impact on the performance or safety of the calliper.

buzzard

subscribed too.

keep up the good work, reliving my B5 days on this thread so its a nice intravenous kick thanks.
bboy82

Subscribed 1 of 3.
reaper

Next up a quick check that the wheels would pass the calliper, which was close, just 2mm gap at the closest point!


I then ordered up some B7 front brake hoses from Doug as MRC had them on the shelf


and also from Audi the front headlight levelling lower arm and rear level sensor mount, as it had completely rusted off the subframe!
reaper

Fancied a change from messing with the front end, so due to a broken rear light from an incident with the window cleaners ladder I went searching for some tasteful LED units.

Was lucky and found a guy selling exactly what I wanted on eBay. Deal was done and a couple of days later they arrived and got installed..



Look great in the flesh, but the down side was a lack of resistors that brought up the dreaded bulb error on the DIS.

Not to worry, I had planned to install LED's through the car and no time like the present so I grabbed the Dremmel, Soldering Iron, Resistors and shrink wrap and modified the relay 387.

Picture before shrinking the wrap the resistors


Picture of completed 387 prior to install
 

Real bonus, No more bulb warnings
reaper

Rear lights were now sorted, so time to get back onto the brakes.

As we are just on the subject of DIS warning's, for some reason while standing the ABS module decide to die and as I couldn't be bothered with the PITA job of opening it up and soldering the broken connection sent it to BBA and 2 days later it arrived back carrying a lifetime warranty!

pjbRs

Have you built a wb before? You obviously got some talent with the spanners.
reaper

pjbRs wrote:
Have you built a wb before? You obviously got some talent with the spanners.


First time out on a WB,

I'm doing the mechical side of all 3, plus all the bodywork on this one as a 'How hard can a WB be' project.

Dont think anyone else has done this, but part from when I have it in the booth for paint the complete body conversion will be done while the car is still being used daily!

The other shells will be off for Aiden to work his magic on
lewiswlawrence

This is a fantastic thread and I am looking forward to reading more, top work sir.
reaper

As the car was still out of use, I installed the repaired ABS module, replaced the washer bottle and wheel arch liner and job done.

No more ABS warning!

The ABS will be off again later in the thread, as all the alloy and plastic components under the bonnet are going to be re-furbed or replaced back to looking like new
RS4Jules

Awesome i will be defo keeping an eye on this  

Next year i am doing one for sure  
cos

Great thread mate , I hope you keep up with all of them As for the brakes , do you have to make an adjustment on abs for the bigger front and rear brakes?
reaper

cos wrote:
Great thread mate , I hope you keep up with all of them As for the brakes , do you have to make an adjustment on abs for the bigger front and rear brakes?


Hi, if using 17z or 18z front and rears togethre there.is no need to touch the abs coding as bias only moves around 2.6% to the back with 17z and 3.4% to the back on the18z setup. So small a difference you dont even notice the change and all is good
cos

I just saw it on the picture that you have the 17z calipers , so you must have the c230 sport package 330x28mm front discs, right?or is it sth else?please enlight
reaper

cos wrote:
I just saw it on the picture that you have the 17z calipers , so you must have the c230 sport package 330x28mm front discs, right?or is it sth else?please enlight


If you shop around for the AMG 320 version discs,  you will find there is a 330 x 30 set available! You can use the c230's but you will find they will rub on the pad lugs at the front of the calliper and you will need to remove material off the calliper mounting points to allow the calliper to move further out by around 3mm  

If you look at the image above showing the edge of the disc and calliper, where the disc is close to the lugs on the right, it will actually touch here with the c230 s disc in place
cos

Thanks mate, do you have a part code for the front discs , as I can't find them?Thanks again
reaper

cos wrote:
Thanks mate, do you have a part code for the front discs , as I can't find them?Thanks again


I will have alook tomorrow and pm you Cos
cos

Thanks mate , you are great
LeeT

reaper wrote:
pjbRs wrote:
Have you built a wb before? You obviously got some talent with the spanners.


First time out on a WB,

I'm doing the mechical side of all 3, plus all the bodywork on this one as a 'How hard can a WB be' project.

Dont think anyone else has done this, but part from when I have it in the booth for paint the complete body conversion will be done while the car is still being used daily!

The other shells will be off for Aiden to work his magic on


Who hasn't done it before? Ive done my car from start to finish on my own on the drive. Which includes the whole WB conversion and everything mechanical including brakes, turbo conversion, facelift of the whole car etc etc etc. My car was a bog standard pfl s4 when i bought it.
 Keep up the good work though, i enjoy reading these threads
colinurquhart

Just think in years to come we'll be doing wide body conversions on the B8!
reaper

LeeT wrote:
reaper wrote:
pjbRs wrote:
Have you built a wb before? You obviously got some talent with the spanners.


First time out on a WB,

I'm doing the mechical side of all 3, plus all the bodywork on this one as a 'How hard can a WB be' project.

Dont think anyone else has done this, but part from when I have it in the booth for paint the complete body conversion will be done while the car is still being used daily!

The other shells will be off for Aiden to work his magic on


Who hasn't done it before? Ive done my car from start to finish on my own on the drive. Which includes the whole WB conversion and everything mechanical including brakes, turbo conversion, facelift of the whole car etc etc etc. My car was a bog standard pfl s4 when i bought it.
 Keep up the good work though, i enjoy reading these threads


Hey Lee, obviously know your car as read your build over time start to finish and know that you WB'd yours on the drive.

Sorry for any confusion, I wasn't suggesting that a WB had not been done by a forum member before, but the details posted so far only relate to the lead up to getting the S4 MOT'd after being stored  completely untouched for about 18 months.

I'm playing catch up at the moment on the thread, as everything posted is from about just over 3 months ago and I only meant things will be different when I get to the point in the thread where the car is back road legal.

As we catch up, you will see that all work from that point has been done whilst keeping the car road worthy for daily use including the conversion to wide body.

It's my daily and required for running the wife in and out of hospital and apart from a few items everything in the thread up to MOT will be getting swapped out including the cayenne brakes as part of my WB project.

Hope that kind of makes sense and there's loads more to share so will keep it coming m8

P.S  Bit off topic, but did that package I sent arrive today?
LeeT

reaper wrote:
LeeT wrote:
reaper wrote:
pjbRs wrote:
Have you built a wb before? You obviously got some talent with the spanners.


First time out on a WB,

I'm doing the mechical side of all 3, plus all the bodywork on this one as a 'How hard can a WB be' project.

Dont think anyone else has done this, but part from when I have it in the booth for paint the complete body conversion will be done while the car is still being used daily!

The other shells will be off for Aiden to work his magic on


Who hasn't done it before? Ive done my car from start to finish on my own on the drive. Which includes the whole WB conversion and everything mechanical including brakes, turbo conversion, facelift of the whole car etc etc etc. My car was a bog standard pfl s4 when i bought it.
 Keep up the good work though, i enjoy reading these threads


Hey Lee, obviously know your car as read your build over time start to finish and know that you WB'd yours on the drive.

Sorry for any confusion, I wasn't suggesting that a WB had not been done by a forum member before, but the details posted so far only relate to the lead up to getting the S4 MOT'd after being stored  completely untouched for about 18 months.

I'm playing catch up at the moment on the thread, as everything posted is from about just over 3 months ago and I only meant things will be different when I get to the point in the thread where the car is back road legal.

As we catch up, you will see that all work from that point has been done whilst keeping the car road worthy for daily use including the conversion to wide body.

It's my daily and required for running the wife in and out of hospital and apart from a few items everything in the thread up to MOT will be getting swapped out including the cayenne brakes as part of my WB project.

Hope that kind of makes sense and there's loads more to share so will keep it coming m8

P.S  Bit off topic, but did that package I sent arrive today?

I will let you know when i get home Phil
reaper

Sorry there's only a few pictures on the next bit, but I had provisionally sold my old faithful Avant and I had 8 days before it was gone to get the s4 MOT'd and back on the road

I will post more images showing the front cayenne set-up when I tear down the brakes and hubs in a couple of weeks for the next stage!

So the rush was on as this was off!


I now had to get those brakes finished quick!

Already had the calliper mounting bolts in the correct grade, but needed some 14 to 16 spacers. Onto the lathe and knocked these up in stainless.


Next up, I installed

1. The discs
2. Bolted up the callipers
3. Tarox pads and retainer
4. B7 Stainless Braided hoses
5. New ABS sensor cages into the hub carrier
6. New ABS sensors

A quick Vac bleed and the pedal was spot on, so on with the wheels and the front was sorted leaving this


and this
reaper

After all that,  I found out one of the new abs sensor was duff, so I got on to Audi and these arrived as a pair and were installed!


As I was running out of time, I knew the rear discs and calliper carriers were shot and decided for speed just to replace with OEM parts, so I ordered the carriers plus bolts, discs and pads from Audi to sort the rear
reaper

Found a couple of extra images this morning from the front refresh that I didn't realise I'd taken!

Hub carriers prior to refurb, don't you just love rust!


The knackered original S4 Callipers after removal


First fit of the discs with the callipers


Side view of the 320 AMG discs showing clearance to the hub carrier and also showing new CV's


And the dreaded Abs Warning due to the faulty replacement ABS sensor
reaper

colinurquhart wrote:
Just think in years to come we'll be doing wide body conversions on the B8!


Now there's a thought!
reaper

With the front end now complete, attention turned to the rear.

Due to the corrosion issues on  the front subframe, I had the test station check out the rear subframe and although very borderline, this would be the last MOT it would pass.

Realising that I would need to get hold of a couple of solid subframes in the near future, I started shopping around.

Luck was on my side as Jimbo had just split a RS4, so I jumped in the Avant and picked up a spare front and rear subframe from him.

The front


and the rear


I completely stripped these down they day they arriving home and sent them for shot blasting and powder coat.

The newly coated subframes will appear later in the build
HHH

Good stuff.

Keep the updates coming.
reaper

HHH wrote:
Good stuff.

Keep the updates coming.


Will do
reaper

While I had been looking around for subframes, I found a 2.8 Passat going cheap with a low mileage engine but shocking body work, no tax or mot.

Car was a perfect donor for some 2.8 heads!

Went to see it and knocked the price down to 230 quid, trailered it home, stripped the heads etc and then sold it on to a breaker.

Here's it going to the graveyard..
reaper

I haven't been able to showing switching out the standard rear brakes as the images were lost due to a Backup Drive failure.

So here is a summary of what I replaced,

2x rear discs
2x pads
2x calliper carriers
Passenger side brake calliper

While under the passengers side, the rear headlight level sensor bracket was also replaced.

So finally on the 29/11/2012 the car was ready for its trip to the testing station for MOT and no big shock that it failed, but not on what I had expected!

Here's a list of the failures



First three were an easy fix

01 - New Bulb
02 - Adjust Headlight
03 - Reduced the gap to ABS ring on passenger side

Number 4 was a PITA to diagnose as 02 kept coming out high.

First checked the Lambda sensors were working correctly, took it to be checked and still O2 was high.

Next, ensured the exhaust had no leaks and ran a smoke test, took it back and 02 was high.

Next found I had developed an intermittent fault on passenger side EGT. These had been replaced as a pair by Audi when faulty in Feb 2011 and still under guarantee so had them replaced. Took it back and still 02 was high.

At this stage had tried all the suggestions off the forum members and had no clue what was up. No errors were coming up in VCDS, the EGT's and Lamba's were good.

Next up as a final attempt, Fuel Trims, timing and fuelling were checked but all were spot on.

Only thing I could think of was that the test station were not giving the car enough time to warm up, so I phoned Ian to let him know I was coming down and took the S4 for a serious thrash

Pulled it straight into the test bay and the emissions were tested and  passed well within limits.

Best bit was the MOT got issued with just an advisory on some scrubbing in the inside of the rear drivers tyre and the rusty rear subframe .

So, on the 9/12/2012 S4 GTF was back road legal after 17 months off the road in storage
reaper

The plan now was to run the S4 nice and relaxed for a couple of weeks to make sure all was good after it being standing for such a long time. 10 days in and without warning it dropped into limp mode on the way back from Bedford.

Pulled over at Corley services and as my mobile diagnostic was still in the car, plugged in to find both EGT's had the dreaded Exhaust Gas Temp Sensor Short to Ground error.

This was now the 3rd time there had been a problem with the EGT's and as a result I decided to research into the physical need for them. After days on the net, there seemed to be no hard evidence for or against running the car EGT Free.

So part one of my daily build starts here.

Coding out the EGT's

We all know, EGT's are not cheap and come with a varied lifespans that can cause much lightening of our wallets/purses. Although I could have my EGT's replaced again under guarantee, I made the decision to get the EGT's coded out.

As the S4 was running standard spec, I realised with my tuning plans that I was in the perfect position to run the car EGT Free through all stages and actually provide real life feedback on the subject.

The approach was going to be simple, 'If I bend it, I mend it' but we'll all then know one way or another if EGT's are actually required or just Audi being cautious!

As Rick from Unicorn will be mapping all my cars, I gave him a call and explained my plans to code out the EGT's. Rick was really helpful and after a few discussion that reinforced my thinking, we were all sorted and I asked him to prep the map.

A couple of weeks later we met up and Rick installed the new EGT Free map and this is how it will now stay throughout the build!

Will be reporting back on this as things progress!
reaper

EGT Monitoring

In order to be able to provide decent feedback on running the car EGT Free and as a form of safety, I decided to install a EGT monitoring system into the car. As I will be removing the volt meter from my RS4 clocks and installing an Omori boost gauge, the next obvious choice was to go for a column mounted pODI  set-up.

Put a call in to Eddie @ WOT Motorsport and he suggested using a pODI housing incorporating a twin VEI gauge with both outputs coded to display EGT temps and a set of Innovate LC1 wideband sensors.

This set-up has now been ordered up , but with a black bezel on the clocks and is ready for collection followed by installation in the next week.



At this point I would like to thank Eddie @ WOT Motorsport for his help to date and looking forward to dealing with him further through all my builds. Cheers m8
reaper

VEI gauge and sensors

Eddie kindly forwarded a few images of my VEI gauge and the revised choice of VEI sensors prior to collection

The all important box


Front of gauge showing blacked out face.


Taken from behind


And finally the sensors


Looking forward to collecting these later in the week
reaper

Seats and Hub Carrier Purchase

While the car had been off the road, I used my free time wisely by stockpiling a mountain of B5 parts, everything from engines to full RS4 panel sets.

I already had a set of Black RS4 front and rear seats, but during a conversation Jimbo mentioned a Black leather set in mint condition. As I was passing to collect some RS4 Aluminium hub carriers from him, I took a look at the seats and they were as good as you'd get so the price was agreed.

I organised to collect them the following week just prior to Xmas, but the wife was hit by a drunk driver as she walked out from work and everything went to hell.

As I couldn't collect the seats as arranged, due to the wife being in intensive care at hospital, Jim was a true gent and held the seats for me for 4 weeks+.

Can't thank Jim enough for this!

RS4 hub carriers, one partial de-greased


Front RS seats being put to good use prior to install
HEKTOR

Loving the build so far phil. Keep up the good work. Everyone is going to be blown away with the quality of your work and the extent you are going to to do something a little different.

Thanks for the kind words. Its a pleasure as always  
S4twiggy

I'm loving this build thread Phil, I like a hands on DIY S/RS owner

Keep it up mate, oh and ill be hitting you up a few PM's shortly about my fitment of 18z calipers
jimbo

   
reaper

S4twiggy wrote:
I'm loving this build thread Phil, I like a hands on DIY S/RS owner

Keep it up mate, oh and ill be hitting you up a few PM's shortly about my fitment of 18z calipers


Keep them Pm's coming m8
reaper

jimbo wrote:
   


Don't forget next time you call its not optional, much    followed by

 
Foxmeister

Nice build goign Phil, will get on more to see it evolve.

Sorry about the mrs, hope all is better for her now.

Just let me know when these bits are ready like we spoke about, still in no rush mate.
ScottR

Possibly a really daft question here, but where do those EGT sensors go?  The probes look about 6" long!  
reaper

ScottR wrote:
Possibly a really daft question here, but where do those EGT sensors go?  The probes look about 6" long!  


Probes can be modified m8!

I have a micro bender that I'll be bending the probes with to suit and then locking the nuts off at correct depth!
reaper

Foxmeister wrote:
Nice build goign Phil, will get on more to see it evolve.

Sorry about the mrs, hope all is better for her now.

Just let me know when these bits are ready like we spoke about, still in no rush mate.


Hey Mick,
Cheers, Hopefully the thread will prove usefull to everyone!

P.s Parts still have your name on m8 just running a couple of weeks behind due to the family stuff!
Foxmeister

reaper wrote:
Foxmeister wrote:
Nice build goign Phil, will get on more to see it evolve.

Sorry about the mrs, hope all is better for her now.

Just let me know when these bits are ready like we spoke about, still in no rush mate.


Hey Mick,
Cheers, Hopefully the thread will prove usefull to everyone!

P.s Parts still have your name on m8 just running a couple of weeks behind due to the family stuff!


Like i said Phil, im in no rush and going by your personal issues of late, take as long as you need pal!  

In the meantime, i want to see some Phat arch goodness here soon!!!  
reaper

Foxmeister wrote:
reaper wrote:
Foxmeister wrote:
Nice build goign Phil, will get on more to see it evolve.

Sorry about the mrs, hope all is better for her now.

Just let me know when these bits are ready like we spoke about, still in no rush mate.


Hey Mick,
Cheers, Hopefully the thread will prove usefull to everyone!

P.s Parts still have your name on m8 just running a couple of weeks behind due to the family stuff!


Like i said Phil, im in no rush and going by your personal issues of late, take as long as you need pal!  

In the meantime, i want to see some Phat arch goodness here soon!!!  


It's a coming, but just to wet the appetite m8 and without giving too much away, u mean something along these lines

Noggymike

^
That's just not cricket!  
reaper

Noggymike wrote:
^
That's just not cricket!  


Sorry, just keeping Mick happy! The thread will move on pretty rapid over the next few days including the first stage of the WB conversion
Noggymike

reaper wrote:
Noggymike wrote:
^
That's just not cricket!  


Sorry, just keeping Mick happy! The thread will move on pretty rapid over the next few days including the first stage of the WB conversion


Mick may be happy

but

Mike's not!


jimbo

reaper wrote:
jimbo wrote:
   


Don't forget next time you call its not optional, much    followed by

 


dont worry, next time il stay over and get horrendously pissed , the following day will be started with a catastrophicly bad head.  
Foxmeister

Your such a tease Phil........Lets see your curves!!! lol
reaper

Seat Removal

With the new seats now here, was time to get them into the car before they became damaged.

A couple of pictures of the old S4 seats.

Front


Rear


Removed the front seats as normal by removing the two small rail trims in the rear and the retaining pin at the front before sliding them out. This was followed by lifting the rear seat base, disconnecting the lap belt from the floor pan and finally removing the mid bracket betweeen the seat backs before sliding then off the side pins.

Seats out of the car







RS4 Seat Install

With the old S4 seats now out of the car, it was time to pop in the new RS4's.

I quickly modified the rear seat back mid support to allow for the different offset on the RS seats, removed the S4 rear seat latch hoops as the catchers were in a different position on the RS seats and finally installed both the front and rear seats

The finished articles...
Front


Rear


Although with a little treatment the seats would look great, they will be off for full refurbishment, modification to the RS logos and I will be installing Backlit Led Screens in the headrests later in the build.

As the rear seat back catches were in a different position and wanting to keep the OEM look, I designed some new retaining brackets that mount to the existing hoop location and once back from powder coating I will upload some images!
reaper

Had a bit of break from the thread due to sorting all things Carbon Fibre, but here goes again.

At this point, the panel donor for this WB project arrived with Jimbo and here's a couple of shots during the dismantle!







reaper

A couple of weeks later, I popped to Jim's in the van and grabbed the gear leaving me with a conservatory like this!

The mutt came as an optional extra!

reaper

Rear Quarter Preperation

I was undecided exactly how much of the rear quarters to use, so I decided to make them as big as possible and cut back to suit once they were loose.

First job was to remove all the spot welds, make up the cut lines and them I trimmed out the rear quarters to leave me these...

Drivers side Quarter...


Passenger side Quarter...


And the remains of the rear quarters...
[/u]
S4twiggy

Looking good phil, coming along now
reaper

S4twiggy wrote:
Looking good phil, coming along now


More to follow
reaper

Fitting the front end

With the rear quarters now prepared and being mid week, I turned my attention to the front end as I needed to keep the car usable.

First, I removed the arch liners, wings, lights, front bumper and engine tray. I won't bore everyone with this as we all know its mostly a load of bolting and a few clips!

Next up I checked over all the RS parts and found I needed to drill and tap out a couple of the wing to bumper retaining bolt holes due to corrosion.

I then bolted up and aligned the RS wings and bumper, followed by installing the arch liners and finally installed the new face lift lights!

Before


And after ....... you just got to love them arches


Luckily, using the Avus RS4 panels against the old Aluminium Silver didn't look to bad!
S4twiggy

Mmmm wideness

Hopefully in future years mine will be WB
LeeT

Coming along nicely Phil!
reaper

LeeT wrote:
Coming along nicely Phil!


Much like your pillar trims
Noggymike

Good work
reaper

Noggymike wrote:
Good work


Cheers, plenty more on it's way!
ScottR

Don't suppose you fancy making some more avant-> saloon seat brackets do you? Quite sure there would be a market for these!
reaper

ScottR wrote:
Don't suppose you fancy making some more avant-> saloon seat brackets do you? Quite sure there would be a market for these!


It's easier to mod the originals, but if someone has issues or would like one doing then happy to help out
reaper

Driver and Passenger side door install

With the wings and bumper in place, next for the swap were the doors.

First up was the removal from both sides of the internal pillar, cill and door trims/cards to allow access to the wiring and hinge bolts. With the internal trims removed, disconnected all the electrical and central locking connectors and pulled these back through the pillar gaiters.

I then stripped the rear door glass and frames from both the S and RS doors and transplanted the S4 rear Glass and Frames onto the RS rear doors. Finally removed the seat belt inertias from the pillars before removing the bolts and S4 doors from the car.

It was then a simple case of swapping out a couple of electrical connectors in the foot-well for the front doors to facelift type and then fit the RS4 door in reverse order to the strip down.

Whilst at the doors, I decided to pull off the S4 rear bumper and test fit the RS4 rear bumper and Side Skirts leaving the car looking like this...

Driver Side...


I know what you'll all be thinking, 'doesn't look too bad!

And then you see it from these angles


and
reaper

As the cars being used daily, it's been funny as hell watching peoples faces and they see the car go past.

Expressions ranging from hello it's an RS4 to WTF

Been priceless!
pjbRs

reaper wrote:
As the cars being used daily, it's been funny as hell watching peoples faces and they see the car go past.

Expressions ranging from hello it's an RS4 to WTF

Been priceless!


Ha ha, I'd do the same.  
reaper

Fitting the Rear Quarters

With the doors in place, time to attach the rear quarters.

First up, a complete strip out of the rear seats, boot trims and rear lights and then laid over a fireproof blanket to protect the glass and paint during fitting.

After about 10 minutes of head scratching as to where I'd finish each edge of the panel off, I did a quick final trim of the RS panels and marked up the S4 quarters.

So starting with the driver's side, carefully cut out the S4 rear quarter and prep'd the face of the panel for welding. A little adjustment followed to get things fitting perfectly and then clamped the panel in place and broke out the welder!

Working in sequence to spread the heat, started to tack the panel in place and repeated the process until it was full seam welded.

One quarter in place...



I then repeated the process with passenger side and followed with a quick flatten of the welds and application of rust inhibitor.



Now that's more like it
pjbRs

Nicely done, is this your profession ?
reaper

pjbRs wrote:
Nicely done, is this your profession ?


No, it's how I relax from work
pjbRs

reaper wrote:
pjbRs wrote:
Nicely done, is this your profession ?


No, it's how I relax from work


Skills mate, I have a pint and a kebab.  
reaper

Blending in the quarters

Next up a quick roughing of the surrounding area and then the application of a few layers of filler.

Roughing and First Fill...



Second Fill...



Third Fill...



Quick splash of paint to see how it's looking and we're almost there
reaper

pjbRs wrote:
reaper wrote:
pjbRs wrote:
Nicely done, is this your profession ?


No, it's how I relax from work


Skills mate, I have a pint and a kebab.  


I have the pint, but kebab sounding good
reaper

Noggymike wrote:
Good work


As promised Mike, some WB action
reaper

A quick comparison

S4 Before...



S4 WB After...



Now the drivers side

So with passengers side almost ready, to go into the booth for spraying I repeated the process with the drivers side and the car is starting to finally take shape.

Drivers side after prep work...

ScottR

Have you done all this on your driveway?  Looks fantastic!
reaper

ScottR wrote:
Have you done all this on your driveway?  Looks fantastic!


Yes, all done on the drive.

Needs about an hour's work on both of the rear quarters just to finish getting the lines perfect Weather turned, so I just got few coats of primmer and a couple of Avus on to protect the panel and seal the filler.

Took 21hrs over a period of five days to get it to that stage, in between using the car to visit the wife in hospital.
pjbRs

reaper wrote:
ScottR wrote:
Have you done all this on your driveway?  Looks fantastic!


Yes, all done on the drive.

Needs about an hour's work on both of the rear quarters just to finish getting the lines perfect Weather turned, so I just got few coats of primmer and a couple of Avus on to protect the panel and seal the filler.

Took 21hrs over a period of five days to get it to that stage, in between using the car to visit the wife in hospital.


That's dam impressive on the driveway. I guess it helps take your mind off your Mrs being in hospital?  
Hope she has a speedy recovery mate.
Roberto Muggli

okkim

What did you do to the inner rear quarters? Have you got any photos of those?
ScottR

Done on a driveway in that time whilst keeping the car drivable. You Sir are a hero!

reaper

okkim wrote:
What did you do to the inner rear quarters? Have you got any photos of those?


I have images of the inner quarter connection coming soon.

Basically a I made an initial trim cut of the RS4 inner quarter at a distance of 60mm parallel from the arch.

If you look at the image below you will see the inner quarter lip around arch, plus a section of the inner arch is missing.



I then placed the RS4 quarter against the car and marked off the edge of the original S4 inner quarter onto the underside of the RS4 inner arch, and marked off at an overlap of 15mm.

The RS inner quarter was then trimmed of along the overlap line and the original S4 inner arch lip was then panel beaten until it contacted with the RS4 inner, before being seam welded and filled.

I have some finishing to do, but the inside of the arch will look 100% OEM when I apply the top coats of paint!

Hope that makes sense, but the up coming images will help!
ScottR

Done on a driveway in that time whilst keeping the car drivable. You Sir are a hero!

buzzard

Loving this thread

It's great to see the passion is still out there.

What final colour are you going for??
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