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Kent

S4 Identity Crisis

The Beginning - Some Brief History

I had been interested in a B5 for quite some time after going to inters in Lee's a couple years back (Black RS4). Once while visiting Matt at Dubforce I saw an S4 on the ramps. I enquired as to what the story was with it and and was told it was in for rings and a part rebuild as it was burning oil. Mat Informed me it was up for sale once finished. A few weeks later the owner got in touch after Mat had given him my number and after running through the spec I knew I had to go see it.

A few weeks after that I was sold and knew it had to be mine. It wasnt the best cosmetically and had some accident damage on the NS Quarter but non of this bothered me as I enjoy messing, rescuing and modding. Without looking at any others I snapped it up as I the work it had received in the past year or so was quite considerable.

This is what I purchased (after a little clean)...



Some of you might remember this from here a couple of years ago. I think it belonged to 'RobEvo?' & 'TomElliot?'

As you can see it needed attention like the front putting back together properly but I was enjoying the K03/K04 hybrids in my first ever Audi / Quattro / B5 etc.

It came with a substantial MRC bill after remap (380bhp) and having egts etc done.

Hardware included:
- K03/K04 Hybrids
- RS4 Fuelling
- RS4 Intercoolers
- Downpipes / Decat & Miltek
- TTV Lightweight flywheel and RS4 clutch.
- 18" Audi TT? Wheels

This car was meant to just be a good fun winter runaround / daily as my MK2 was in pieces. Just tidy it up and run it I said to myself. Well that lasted all of about a week as I had to buy some Recaros for it...



Right thats its I said to myself, just look after it and enjoy it.. Dont spend any more on it.
Kent

Whoops

So much for looking after it and not spending any more money on it. After my bro lost his fight to cancer and my mate suddenly died shortly after I didnt step foot out of the house for a couple of days. When I decided venture out my head was still obviously up my @rse and in a daydream as driving along our road I suddenly found myself going sideways in the snow. Quickly countering to miss a BMW, then a wall I eventually found myself running out of road so had to park it in a flower bed...



B0llock5!

Got off lucky as no bags deployed so after dragging of a rock I drove it home and quickly got onto fixing it. This was my introduction to the man that goes by the name of Jimbo. Front panel and rads later I started stripping it...



All I needed then was some headlights and a bumper. Enter stage left... Reaper. Perhaps this accident was fate as my path was obviously meant to cross with these two people.



On closer inspection I realised the oil pan had cracked in the most minor way possible. Obviously it couldnt be just the bottom half I had to be the upper so I ended up having to drop the subframe.



Anyway after a few weeks off the road (struggling to find some parts etc) I was back up and running...

Kent

Some Little Treats

After all that I thought i would treat it and myself and get a few little treats to brighten up the cabin. The steering wheel was in a horrendous state all shiney and dirty and old. So after a little deal with my mate MJ i had a nice new steering wheel...



The gearknob was the same. Rather than buying an aftermarket job or whatever I thought id have a look at refurb mine. The knob and gaiter was redone in some leftover black nappa i had for the MK2 and I took the gearknob cover to pieces. I scratched all the gate detail and black paint off the underside and sanded down the little lug then replaced the information with a self-adhesive print on clear in mirror with a white back lam (one of my business is graphics printing). A quick polish of my knob (ooo-er) down to fine grade and i was left this this...



Why the RS4 I hear you all cry its only an S4!!!! ARGGGHHH how dare you??!!! Well after spending many nights browsing the forums I knew my mission was clear. Although one of the first (pathetic) little mods I thought I would start as I mean to go on and this would help me stay focused on the prize!
Kent

Gearbox

So it wasnt long I was back on the road until a noise started from the gearbox. Amazing! Sounded like a bearing and got progressively worse. Not wanting / being able to take the car off the road for too long I set about finding a replacement that I could swap out. Managed to get my hands on this one (RS4... obviously). (Massive thanks to Abdul on this).



Its got the common 1/2 hub issue so I got looking at replacement parts. After coming accross JHM I thought it would be rude to not to do some upgrading atleast while im in there! More on this later.
Alex@Fontain

You're doing a nice job there; some very tasteful additions
stuartx

Sorry to hear of your loss buddy, been there and know its not easy, stick in though, keep busy and doing what your doing good work.
Kent

Cheers lads. Last year was just surreal with everything going on in family and business life. One positive from last year that enabled me to get through it all and have some me time was meeting two like minded individuals who I've taken on a unit with. I've always wanted my own little place to tinker.

So watch this space... much much more to come!
reaper

Obviously after our chat's over family issues on both sides, onward and upward bud

Good luck with the project 'K', looking forward to seeing the rest unfold
   
RS4Jules

So sorry about your losses but glad you have found something to try and keep your mind busy  

I am tuned into this and cant wait to see it develop.
Yep you cant go wrong with MJ hes a top bloke,that steering wheel looks like one he leant me a while back while trimming an r32 one for me lol.

Also lovely touch with the gear knob,i love little attention to detail things like that  
Kent

Yeah life sure can be crazy Reaper as we all know. Just got to live it and make the most of it while you can. Can't worry too much about the consequences as long as your not harming anybody.

Your the 'attention to detail' king Jules. Im the same. I love things that keep you guessing for ages and then its like 'ohhh and he's done that i didnt notice that'.

I've had the chance to spend quite a bit of time up close with your B7 down at Juniors. Im don't dig all the air like all you bag fiends but really is a lovely motor. Top job. I'll admit the B7s do look completely MOBB when dropped on their arse.

Is that black B7 one of your boys down down there now?

Edit: And no its not 'the loner' wheel thank you very much!  
RS4Jules

Yes thats my mates,in fact ive helped him alot and its going to look pretty mega,i think its still sitting on my old rotors  

Yes i totally get the air thing but its shocking how good it is now.Mj is also doing a few bits for my old golf wagon at the minute too in the brown bentley leather.

Your comment re the details is exactly how i see it,like some will just see ow it has nice wheels and air but the big thing is finding all the small touches that inhance it all.

This is exactly what im trying to achieve with this old allroad im doing and theres one mod i love thats never been done before but i know alot wont even notice as not many people know about allroads    

Im due to visit MJ soon so i will send you a pm if your about mate    

Anyway,this is about your b5 lol,very jealous as im really into the saloons atm so cant wait till i can have a bash with one.

Keep up the great work  
Kent

Yeah do. Im normally not far away.

I could do with your expertise as chief wheel whore anyhow at some point over the next few weeks. Need some help with spacers.
Kent

Bad Boy Sounds

As the B5 comes with poxy speakers that were failing on me the next thing on the agenda was to sort the sounds. I wouldnt exactly call myself an Audiophile but I do love music and I do really love at least semi-decent audio equipment.

I dont drive everywhere on number 11 but I do like being able to turn up my system to whatever i desire depending on what im listening to and what mood im in.

Bass has got to kick and drop and mids and highs need to completely immerse you in sound in my book.

A few weeks ago i dropped in on my friends at Audio Images (Bradford) for somewhere to do the work that was clean and warm and for my friend Khalid to help and advise. For those that might of known MJ's G60 'back in the day', Khalid built the competition system in that. (Horns under the dash etc).



In it i decided to put:
- Kenwood MP3/IPOD/CD/Bluetooth hands free head unit up front. (you can change the illumination and buttons through 10 colours but the Red is perfect next to the S4 interior illumination and the black facia looks well in the console... i hate aftermarket units that dont match and really stick out in the cabin)
- Upfront - Focal Access 130 (5.25") 2 Ways.
- Rear Shelf - Focal Access 165 (6.5") 2 Way Co-axial.
- Massive Audio 4 x 80w RMS @ 4ohm (to power the fronts and shelf)
- Massive Audio 1 x 600w RMS (to power the 2 12s)
- 2x Massive Audio 12" Subs (in a ported box)



Little details...
- Completely ripped out all the existing system and cables (i cant stress how rubbish factory cables are)
- Power - I ran two fused supplies from the battery via a gland i drilled into the ecu box (later filled with silicone), down into the drivers kick panel and rearwards in the door trim.
- RCAs - As the Kenwood has 3 pre-outs I can control the cross over from the head unit. So i ran three pairs in a loom to the rear via the passenger footwell and rearwards down the door trim. (all these cables came out nicely under the rear bench.
- Amp Mounting - I fixed neatly to the rear of the one of the fold down benches.
- Speaker hole conversion - I used the 'Concept2' adaptors to convert the rear shelf from square to round 6.5". And same again to step up the pathetic 4" drivers to 5.25". Here i modified the adaptor by shaving some of the little 'legs' off it. So I could double sided tape it to the card and then screw it. The design wasnt very good from Concept 2 as it would have left a gap which is a big no no. Its all about a good solid seal with door speakers!
- Front Doors - by removing the casing on the focal tweeter i could locate it back in the original Audi location and fix it in place with the OEM fastener. The crossover I located on and glued onto the bottom rear of the card and sticky pad & cable tie the wires neatly. I cut away enough of the big foam block in the door to make room for the crossover when the door card was mounted.

All mounted up...



After building the car back up and tweeking with the settings for a good hour I was a happy boy. I was semi-worried the 5.25" weren't going to impress me after always been used to 6.5"s up front but I was amazed.. they really sound good. I think this is pure testament to how solid we were able to mount them in the door card (more time spent on this the better). I can crank them up with no distortion. (I set my all the gains on my setups to distort at say 29 (if the max vol on headunit is 30). This way I have full progressive control over the volume. I've just got to keep idiot friends away from the volume control.)

The coaxs in the shelf fill the rear of the car perfectly and support the fronts nicely. It's amazing how much better audio sounds in a car like an audi in comparison to something like an old golf. They are worlds apart in how they handle the sound. And the subs... well they don't need any explaining. Junk in the trunk...

Noggymike

Awesome

Great work considering your recent sad events.

M
Kent

Cheers dude. Going to be coming at you thick and fast over the next few weeks!
Kent

Some Bits & Pieces

I decided the front indicator lenses i bought with the headlights from Reaper were a little dirty on the inside and could do with a wash. I stuck them in the dishwasher. Like an idiot i washed them on 90 and all the silver reflective stuff started flaking off. Like a bigger idiot i replaced them with new items from TPS at 45 ish quid each when I knew the prefacelift style just were not cutting it (has anybody else had problems with them sending the wrong style lenses (the sort of frosted kind)?).

Sods Law but Jimbo got in touch pretty much immediately after to let me know that he now had some RS4 headlights up for grabs. After a friday night blast past Skipton I came back with some RS4 goodies!...



I didnt appreciate how the carbon trim pieces were all different on the RS4. Obviously the Double Din centre console didnt come with the trim as this needs to be sold with the door trims etc. I have my own plans for the internal trim so all i needed was some that would fit my console and wasnt really bothered what they looked like. After thinking id struggle to find any suitable, somebody got in touch from a wanted ad and I had some wood effect trim in my possession (for a very reasonable price, thank you whoever you were!!).



I quickly refinished them in Schwarz Black...



And got to work fitting my RS4 headlights...



I noticed as it was getting wetter the car was very damp inside. I had replaced a perished boot seal earlier which had caused a damp boot but it was still bad and getting worse. After some forum searching i quickly found the problem in the drain holes up front making water in the cabin. I removed the rubber grommets but unfortunately I realised the car was full of water on the drivers side / rear footwell. I removed and slung the carpet as it had seen better days...



After taking out the carpet and only putting one seat back In i couldnt wait to take it for a spin. Maybe its just in my head but that little weight loss sure does seem to make it a little more lively. Also less sound deadening makes you feel like your more connected to the car (plus a pseudo dog box in the form of a knackered gearbox bearing sounds pretty cool haha).
Kent

Kid In A Candy Shop

Now im ready to get down to the juicy stuff. After sealing a deal for some more bits and pieces I drove down to London last week to collect this...







After loading up my van of treats I noticed they also had what ive been on the look out for a while now...



Understandably they wouldnt split from the rest of the interior so I took the whole lot. There is a pair of ok nick RS4 Recaro front seats going if anybody is interested (will create a sale ad this week with pics)??

After a Burger King I hit the M1 to bring all the loot back.
reaper

About time you got them pics posted up and let the cat out bag m8
reaper

About time you got them pics posted up and let the cat out bag m8
Kent

Yep.. It's internet forum official!
stuartx

Watching this with interest and here was me looking at the grill thinking, you should sell the RS4 badge
RS4Jules

Yes mate  

Was talking to mj about this saturday lol.

I dont think he quite realised how sought after widebody s4's are    
Kent

stuartx wrote:
Watching this with interest and here was me looking at the grill thinking, you should sell the RS4 badge


Haha I get alot of that flack dont worry! In my head its my motivation to get it done sharpish to the point where it can wear it with pride!
Kent

RS4Jules wrote:
Yes mate  

Was talking to mj about this saturday lol.

I dont think he quite realised how sought after widebody s4's are    


I stood him up for training as i was too busy in my element fitting panels haha.
ibzzzzz

Very nice to meet you and do business pal. Hope you liked London too. Do keep us posted of the build. Ill have that bracket out to you tomorrow just been busy wrapping up the RS4...... thanks again.

Ibz
Kent

Yeah man! Good to meet you also. Panels are going on as we speak. Pics to follow!
ibzzzzz

Whatsapp me the pics
Kent

Wide Body Day 1 - Doors

So it begins! My plan of attack was to start with something easy. I decided it needed to be the doors as once i had swapped them over for the 4 RS4 items i could use the existing front wings and rear qtrs as reference points for the lines and gaps.

Last thing i wanted todo was to drop it all to pieces and then have to put it all back together with little to work from. Also as this is my daily I have todo a days work on it and ensure its back together to drive it home.

I realised the loom had been cut on a few doors so I had to swap these out also. The the RS4 window frames were retained on the front as they are slightly different to the PFL S4 items in how they fix. The doors didnt come with wing mirrors so i had to swap the originals over to the new frames.

Obviously the rear door window frames are massively different between RS4 Avant and a saloon so these needed to be swapped over. By the last one i was obviously getting a little tired as i removed the RS4 frame and then completely refit it. I only noticed when i shut the door and the glass nearly smashed. Good one Kent.

Gapping Tips:-
- Vertical door gaps top and bottom are adjusted by the hinge connecting to the A and B pillars (bolts accessed from inside and outside).
- Flushing the panels with the adjacent is done by adjusting the hinges connecting to the door (accessed from the door shut).
- Further adjustment on the catch brings the doors in/out and up/down at the rear.
- Window frames need loosening off and then doors closing carefully then nipping up. Then further small adjustments to ensure a good seal.

A little slide show...
 


Got a little bit giddy when i saw this for the first time...



Close up...

Nez

Looks great another widebody
lynchy

Subscribed  
FalleN

Good job! Gonna follow this one
jbh

great work so far.

Subscribed
mikey-s

I haven't even started cutting mine yet!   Must try harder!
Kent

no cutting as of yet Mikey! Tomorrow the real stuff begins
reaper

Kent wrote:
no cutting as of yet Mikey! Tomorrow the real stuff begins


Measure twice, cut once
Noggymike

reaper wrote:
Kent wrote:
no cutting as of yet Mikey! Tomorrow the real stuff begins


Measure twice, cut once



Then get the grinder out
Marc R

Your pics don't work...but..subscribed
Noggymike

Marc R wrote:
Your pics don't work...but..subscribed



Must have deleted them from Photobucket or something
Kent

im trying to figure out what ive done! i think i made a booboo trying to organise my photobucket into albums.

trying to sort now.
Kent

Wide Body Day 1 - Doors

Wide Body Day 1 - Doors (SORRY FOR REPOST - BROKE PHOTO LINKS & COULDNT FIX??

So it begins! My plan of attack was to start with something easy. I decided it needed to be the doors as once i had swapped them over for the 4 RS4 items i could use the existing front wings and rear qtrs as reference points for the lines and gaps.

Last thing i wanted todo was to drop it all to pieces and then have to put it all back together with little to work from. Also as this is my daily I have todo a days work on it and ensure its back together to drive it home.

I realised the loom had been cut on a few doors so I had to swap these out also. The the RS4 window frames were retained on the front as they are slightly different to the PFL S4 items in how they fix. The doors didnt come with wing mirrors so i had to swap the originals over to the new frames.

Obviously the rear door window frames are massively different between RS4 Avant and a saloon so these needed to be swapped over. By the last one i was obviously getting a little tired as i removed the RS4 frame and then completely refit it. I only noticed when i shut the door and the glass nearly smashed. Good one Kent.

Gapping Tips:-
- Vertical door gaps top and bottom are adjusted by the hinge connecting to the A and B pillars (bolts accessed from inside and outside).
- Flushing the panels with the adjacent is done by adjusting the hinges connecting to the door (accessed from the door shut).
- Further adjustment on the catch brings the doors in/out and up/down at the rear.
- Window frames need loosening off and then doors closing carefully then nipping up. Then further small adjustments to ensure a good seal.

A little slide show...


Got a little bit giddy when i saw this for the first time...



Close up...

Kent

Wide Body Day 2 - Front End

Wide Body Day 2 - Front End

After putting the doors on i couldnt wait to get cracking on the front end. I just had to see the wings drop on.

First it was get it up on some stands, whip the bumper off, remove the shit guards and take off the cill trims and the wings. Then it was on with the RS4 badboys!:



Front bumper on and bolted up to the wings it started to look more and more like the real thing:



Just like the rear doors overhanging the quarters the new front wings overhanging the original wheels gives a real indication to the difference it all makes:



I got excited!:

Kent

Wide Body Day 2.5 - A couple of bits and pieces

Wide Body Day 2.5 - A couple of bits and pieces

As the front wing had a small dent the seller kindly agreed to have this fixed prior to my purchase as part of the deal. I was slightly dubious as to how well it was going to be done but i must say it was good. You couldnt even tell from the rear of the panel where it was.

They had put some primer on it so i thought i would treat it to a lick of paint so i didnt feel like i was driving a complete cut and shut.



Then swap the PFL bonnet with the RS4 FL style bonnet and drop the grill back in...



Id being driving around with one drivers seat, no carpet and no rear bench for a few weeks. Thought id get my act together and at least drop some seats in even if i hadnt got a new carpet yet.

After measuring up the factory standard rear bench seat backs against the RS4 items it looked asif they were pretty much the same width. However, the 40 split fell a little short of the side fixing when in place in the middle bracket and the 60 split looked a little too big for the original mounting brack (by the same amount the 40 split was short).

Easy and obvious answer was to ammend the centre fixing bracket to bring it over to the near side a little bit and split the difference between them.

40 split located in centre bracket showing how its a little short on the outer bracket...


60 split located on outer bracket in ideal spacing with middle bracket loose (original bolt holes show how the bracket needs moving over slightly)...


Centre bracket cut, rewelded and redrilled and voila...


Still need to fabricate a new fixing for the seat back uprights using existing mounting holes but thats a nice little job for another rainy day as i have more pressing matters at hand!

As she sat at the end of the weekend...

jimbo

   
Dane

Excellent work!
stuartx

Coming along well
guymcc

Great work!
Noggymike

Speedy work  
Kent

when your driving a car with no carpets, seats, numberplate, doorcards, doorhandles, cant put windows down, leaks in water, massive gaps in your doors, three different colours of paint etc etc as your daily it kind of gives you the motivation to get it done as soon as possible haha.

to be honest its been manic at work so ive only managed to spend a late night and a half a saturday each week at the moment.

if i could i would have loved to just take the week of work and take my time enjoying it a bit more. pressure of having to get it back drivable before you can go home to bed is a bit of a pain.
Noggymike

Kent wrote:
when your driving a car with no carpets, seats, numberplate, doorcards, doorhandles, cant put windows down, leaks in water, massive gaps in your doors, three different colours of paint etc etc as your daily it kind of gives you the motivation to get it done as soon as possible haha.

to be honest its been manic at work so ive only managed to spend a late night and a half a saturday each week at the moment.

if i could i would have loved to just take the week of work and take my time enjoying it a bit more. pressure of having to get it back drivable before you can go home to bed is a bit of a pain.



Try renovating a house while still living in it      

Gr8 work tho
Kent

thats easy! as long as you have a bed to sleep in and something to sh!t in your fine! (unless youve got a partner and kids in which case the ear ache factor needs to be taken into account)
ASK3L

Kent wrote:
when your driving a car with no carpets, seats, numberplate, doorcards, doorhandles, cant put windows down, leaks in water, massive gaps in your doors, three different colours of paint etc etc as your daily it kind of gives you the motivation to get it done as soon as possible haha.

to be honest its been manic at work so ive only managed to spend a late night and a half a saturday each week at the moment.

if i could i would have loved to just take the week of work and take my time enjoying it a bit more. pressure of having to get it back drivable before you can go home to bed is a bit of a pain.

How's it a pain if you've only had ONE night as you said
Looks great though, hope it comes together soon.
Kent

thanks! but i actually said ONE night and HALF a saturday (second half of the day (ie another night)) EACH week (ive done two weeks ish on it now... so approx 4 nights.

and its no where near finished!! things are only just getting cracking!!

and please dont get me wrong.. everything is relative... mucking about with my car will never be a pain. i did just mean it would be so much more enjoyable if i could just sack everything else off and spend some proper time on it!
Marc R

i know that feeling all too well..
Noggymike

[quote="Kent:594234"]thats easy! as long as you have a bed to sleep in and something to sh!t in your fine! (unless youve got a partner and kids in which case the ear ache factor needs to be taken into account)[/quote]


Welcome to my world    
frazz82

[quote="Noggymike:594413"]
Kent wrote:
thats easy! as long as you have a bed to sleep in and something to sh!t in your fine! (unless youve got a partner and kids in which case the ear ache factor needs to be taken into account)[/quote]


Welcome to my world    


My world aswell   only time I have to myself is when I take a dump  

Good work Kent it's really coming along
Alps

Bloody heck Kent! That was quick!

So is it ready for the paint job now?
Kent

haha somebody even followed me into the single mens toilet at work the other day! i thought bloody hell i cant even take a sh!t in piece anymore.

cheers guys got the bit between my teeth now.

still a good couple of weeks before i can prep it to paint but broke the back of it now.

today was a good day! will post pics tomorrow hopefully.
BNBboyo

great work and condolences about your brother matey
Kent

Wide Body Day 3 & 4 - NSR Qtr

Wide Body Day 3 & 4 - NSR Qtr

Onto the juicy stuff!... Thought i would start with the NS rear quarter as it doesnt have a fuel filler cap to worry about (not that i saw it making too much difference).

First up was to cut the panel out of the donor car. I cut the face of the panel larger than i needed, drilled out the spot welds down the door and cut out the inner arch leaving plenty on in here to be safe. Obviously its easier to take more off than add it back on!



Time to go under the knife car. So in she came and up on axle stands (both sides so it was sat balanced, wouldnt be cool if the chassis skewed as the side was cut out). Trimmed the outer lip of the S4 arch away to allow the RS4 panel to be offered up. Here we could determine where the joins were going to be made.



Outline of the panel was marked then i cut away loads more of the S4 panel to allow the RS4 panel to offer up further especially so i could see where the inner arch would marry up...



It was decided to go against the grain and unlike some of the other conversions ive seen we'd do the top join just under the top line. I bowed to the advice of my good friend Andy who was a panel beater for 25 years. He explained that it would be easier to loose the join into this line than in the middle of a flat panel and it would also be stronger here so less prone to distortion / cracking. Rather than butt join the panels we also decided to lap join the panel. Again the double skin would give greater strength...



Having not done a WB conversion before (or much panel work even) the whole process was really interesting to get my head around from start to finish. Having only studied the various pictures available on the web (MRCs build etc) and some welcome advice from Reaper on how he did his it was good fun to work my own way around the works.

This was favourite bit of the task and anybody who has done the conversion will know the issue with marrying the wider width of the RS4 panel with narrower S4 panel. It was bits like that this that you don't really appreciate from looking at a few photos on the internet. Its these bits that will be interesting to see how others tackled the problems. Alot of the joins were fairly obvious and straight forward but to me this was the test of how well you married your S4 with its new RS4 skin...



Here the panel was cut all the way back to the light so it would feather in well and gradually over the distance of the panel so it was a nice and smooth transition. The difference in width was approx 15mm between the panels. A small piece was welding in to patch.

All the joins were then finished welding and ground down...


Bit of primer to just to add some protection for the time being and the all important checking how it gapped up with the existing panels...



Beautiful!! (its all about the gaps if you ask me, i love a good gap!)

This was looking the down the join on the panel before filler (just some primer)...



The following day was filling and blocking down the panel. It didnt need too much but most of the work was down at the bottom of the panel near the bumper where the panel was spliced. Then it was on with some primer. I also offered up the cill trim... this completely set it all off!...





Last but not least i had to finish up the welding in the inner arch. I found this was the biggest struggle as it was all awkward welding upside down / on your back and crammed in a wheel well. I quickly had to treat myself to one of those crazy welders caps to stop my hair setting on fire every 2 mins. One went in my ear which was quite painful.



Then it was clean up the whole area with a wire wheel on the grinder (also fun in tight spaces) to remove any rust, old paint and seam sealer. I treated the whole area with rust treatment, primed it with Bonda anti rust zinc primer and then it was time to crack out the sprayable seam sealer. I can't recommend Innotecs Spray Seal enough. Really good for imitating that OEM factory look...



As its covered by the bumper i thought i would also Seal the rear join...



A couple of random shots in my car park at work. Starting to look like a bit of a beast if you ask me...



Ron

nice work and good detailed pictures!

which rear bumper are you fitting?
Kent

Cheers Ron.

Its a tough call. Obviously its not just bumper choice but also what im doing with exhaust etc which im not quite ready todo yet.

I know it divides opinion but im swaying to RS4 at the moment. Quite like its bulkyness as its sort of in keeping with the rest of the panels.

Also after trimming some off it so i could offer it up its apparent that it will be quite a mod in itself getting it to look right and last which i quite like...

reaper

Coming on now m8, hope the info has helped and looking forward to more updates on side 2.

Dont think much of your rear bumper mod  
reaper

Personally i think the bumper choice is mainly down to the final colour, as the RS does not suit all colours!
Kent

whats wrong with my bumper mod?!!! thats a top class job for Bradford!

was thinking with the bumper as i can swap them out in four bolts i can always do a couple of options
stuartx

Looking gid
coullstar

Some good work there.  I think I prefer the S4 rear bumper design.  A lot simpler.
Ron

I prefer the Rs rear bumper too as you say its in keeping with the rest of the panels, an S4 bumper just looks like the easy way out to me
Dane

Wow, such quick and good work. Love it!
Akis

Awesome work Kent! Inspiring stuff indeed

I think the RS4 rear bumper will set off the wide body nicely but I agree with reaper that some colours may not suit it.
Kent

Thank you very much. I must admit ive never done a build thread before but everybodys kind comments are spurring me on! Im enjoying updating you all.

Yeah i sort of agree with the colour thing. For instance the current Avus colour pictured above doesnt work on the bumper in my opinion (granted its not fitted properly). But i think in a bright shiny colour it will look so much better.
Marc R

RS4 bumper looks awesome in dark colours IMHO.

If I were you I'd fit it.
Jamo

Having seen them up close many times in Aidans workshop I prefer the OEM bumper on the S4 to the RS4 one for a WB, just doesn't look right at the rear for me.
Nez thread has pics of both, see which one you like
Kent

See... a few different opinions in few different answers.

Its definitely getting fit even just to see what it looks like. I've chopped some bits of it now so might as well.
Kent

Wide Body Day 5 - OSR Qtr

Wide Body Day 5 - OSR Qtr

After a manic week at work i managed to escape on thursday evening to have a pop at the other quarter.

Before i did anything i put the old Rivetnut gun to good use and did some work on the NS cill trim. After i had offered it up last week i was eager to get it on.

After drilling out the rivets of the S4 cill trim mounting thing and prying it off i offered up the RS4 cill trim and made sure it all lined up with the wings etc and sat into the cill ok. I marked it up in the centre of the holes and drilled them out. Prior to popping the M6 rivet nuts into the the holes i sprayed some more bondo anti rust zinc primer into the holes for protection.



Really sets everything off when the cill trim is on...



Then it was time to get busy again. I got quite engrossed in it this time so didnt take as many pictures but in all fairness its exactly the same as the other side only you have a different profile on the inner arch which was a little trickier to get right. The fuel tank is on this side so watch that and the central locking pump is also tucked away in the bottom of the rear qtr which needs to be moved before it is set of fire. The panel gave a bit more of a fight to fit and get right but wasnt a problem in the end.





Then after pushing myself a little too much and crammed in the wheel well backwards with an angle grinder (cant wait to get my air tools sorted) a disc gave up on itself and bit me straight in the face. The second it happened i knew it could have been nasty but i was quietly happy to look in the mirror and not be horrified...


There is no rush to get the car done. So far i have done quite well i think progress wise and have enjoyed every min. Dont start endangering yourself kent just because your tired. After i stopped shouting at myself i consoled myself with the fact that i was very lucky and chicks dig scars.  I downed tools and got the car back on its wheels to go to bed. I literally bleed for my builds!

More this weekend.
Marc R

Good progress again!   Grinders can be nasty when out of control...got one in my hand some time ago.

Challice

Great progress, cars looking ace...
Noggymike

Great work

You are right about the cills making all the difference



I did the same with a grinder many years ago grinding out the arches on my XR2 for some bigger wheels.

Right in the eye,luckily no lasting damage.

PPE for me after that
Kent

When i was building the MK2 cleaning up a bolt it nicked and shot up straight in my eye.

I thought it was just the bolt that had struck me and carried on all day barely able to open my eye.

When i got back to work i ended up having to get one of my staff to lay me down and pull a strand of wire wheel out of the corner of my eyeball.

After then ive always worn my gigs. Doest stop a blade to the face it would seem.
Kent

Wide Body Day 6 - OSR Qtr Finishing Up

Wide Body Day 6 - OSR Qtr Finishing Up

Still had some welding and finishing up of the OSR quarter todo. Really again it was just a repeat of the other side.

First up was a light skim of filler and rough block down the outer wing then a quick prime to protect it for a short while...



Then turning the attention to the inner arch it was clean everything up, preventative rust treatment, primer, sprayable seam sealer (sorry pics aren't that exciting)...



Bit the bullet and ordered a set of the most overpriced plastic grills and clips in the world. Wasnt going to fit them until the final build but couldnt handle having them sat about in the house. Thought id try tidy the car up a little. I even bought some number plate stickies and put that on as i was getting bored of petrol stations refusing to serve me (i dont know why when im driving a cut n shut sporting massive scars on my face)...



Then i treat it to the biggest mod of the past few months in my opinion. I used a tool called a sponge in a bucket and tried out some product called water and soap...





Made a massive difference and looks a little more like an actual car now. Really starting to get excited!
guymcc

Getting there Kent!  Not long now!
Rasss-4

Good going there  
Cracking on with it, will look pphhhhhaaaaaatttttttt
RS4Jules

OMG Kent this looks amazing.

The war wound was defo worth the hard work,tbh looked pretty tough when i saw you lol.

Defo catch up soon  
stuartx

Good work buddy, keep it up.
C J

It is looking epic for such a small time period of work!!

It does make me chuckle when people wb an s4 and keep the normal wheels on! The tuck looks comical! Lol!!

Keep the picture updates coming!!
Marc R

How far off is the offset now?  i assume you need atleast 20mm spacers with the WB kit on (using oem RS4 wheels)
Kent

haha the tuck is hilarious. view the car side on and all looks ok. walk to the front of the car and just watch the wheels completely disappear.

tbh ive never been terribly clued up with wheel offsets, tyre fitment etc etc. Ive never taken the time to learn so i normally just keep trying things until ive got it right. Im not normally that far off.

Just in the process of sorting spacers for my new wheels for a trial fit before i have them refinished.
reaper

Marc R wrote:
How far off is the offset now?  i assume you need atleast 20mm spacers with the WB kit on (using oem RS4 wheels)


Marc,
If using OEM RS4 ET20 wheels no spacers required unless you want to push them out further than they would normal sit on the RS!
Kent

Ahh Trick question!! I got it. Yeahhhh
Noggymike

Kent wrote:
haha the tuck is hilarious. view the car side on and all looks ok. walk to the front of the car and just watch the wheels completely disappear.

tbh ive never been terribly clued up with wheel offsets, tyre fitment etc etc. Ive never taken the time to learn so i normally just keep trying things until ive got it right. Im not normally that far off.

Just in the process of sorting spacers for my new wheels for a trial fit before i have them refinished.



I wasn't sure either

http://audisrs.com/about50831.html
Kent

Wide Body Day 7 - Rear Bumper (Teaser shots)

Wide Body Day 7 - Rear Bumper (Teaser shots)

Had a bit of a manic time at work so haven't been able to progress as much as i would have liked recently.

Plus im on the RS4 rear bumper conversion which to me is one of the trickiest parts of the whole job to be honest. Cock this up in the slightest way and all the hard work so far counts for nothing as any error here will be massively obvious. And its easy to get wrong.

i've never done anything like this before so i've spent the last couple of weeks researching everything plastic and getting myself organised with what i hope is the correct tools and materials.

With one last ponder as to whether i was going about it in a good way it was time to chop!

A few teasers from this afternoon and tonight (in the kitchen).

RS4Jules

Yes Kent i am so watching all this and the rear bumber is defo something that needs to be nailed for the overall look  
Marc R

Me too
B5QUAT

Awesome thread with some great pics. Bit beyond my skill level but will keep my eye on this with interest.
Tony K

Love to see step by step build threads with dramatic changes.

Keep up the good work, I'm following this now
Kent

Wide Body Day 8/9/10/11/12/??? - Rear Bumper

Wide Body Day 8/9/10/11/12/??? - Rear Bumper

I cant begin to explain the pain i've been through with the rear RS4 bumper conversion.

After many days of on and off and tweeking and re-evaluation and cocking up and starting again and ally welding and glues and fasteners and plastic welding and having to buy a second S4 bumper (thanks confusionhunter) i have almost got it looking somewhere near (i think).

TA DA....



I welcome all feedback positive and negative.. i've been staring at it that much and its pushed me so close to the edge i honestly cant decide whether i hate it or love it. I think i just need a bit of time apart from it ha.
Marc R

This makes two of us KENT...the rear bumper is a f*cking big pain in the ass,,,,took my mate 4 FULL days    to fix it.
hereford

Re: Wide Body Day 8/9/10/11/12/??? - Rear Bumper

Kent wrote:
Wide Body Day 8/9/10/11/12/??? - Rear Bumper

I cant begin to explain the pain i've been through with the rear RS4 bumper conversion.

After many days of on and off and tweeking and re-evaluation and cocking up and starting again and ally welding and glues and fasteners and plastic welding and having to buy a second S4 bumper (thanks confusionhunter) i have almost got it looking somewhere near (i think).

TA DA....



I welcome all feedback positive and negative.. i've been staring at it that much and its pushed me so close to the edge i honestly cant decide whether i hate it or love it. I think i just need a bit of time apart from it ha.


For my money, if you're going WB saloon/sedan then you still need to carry the RS4 rear bumper; but hey, that's just my opinion...
C J

It looks spot on to me to say its in primer and grille-less!!

I'm with Hereford, you don't fit 99% of the rs body work and leave the bumper! All rs wb or nothing!!

Keep up the good work!
Kent

Marc R wrote:
This makes two of us KENT...the rear bumper is a f*cking big pain in the ass,,,,took my mate 4 FULL days    to fix it.


That makes me feel a little bit better. If I had been able to keep at it constantly then it would of been a solid weeks work. With all the breaks in between to regroup, find a new bumper and work/family commitments etc its taken me about a month.

I'm thinking in the not too distant future im going to have a look at getting a mould taken off it just in case i need another or somebody else wants one.

I know i could do it quicker now but i cant help but think if some poor soul bumps into the back of me i'd drag them them out the car and give them a pasting.
Kent

C J wrote:
It looks spot on to me to say its in primer and grille-less!!

I'm with Hereford, you don't fit 99% of the rs body work and leave the bumper! All rs wb or nothing!!

Keep up the good work!


Cheers. It's really spurred me on now that its starting to look like a car again now and not some write off.

I definitely agree that it 100% needs something going on at the rear. Whether its RS4 bumper or some sort of diffuser or exhaust set up.

Its a bit of a shame having beefy RS4 panels when viewed from all angles apart from when somebody is pulled up behind you. It definitely needs some sort of drama going on!
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