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 Never Say Never Again - One DIY project too far... View next topic
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ScottR
Veteran


Car: B5 S4

Joined: 22 Apr 2008
Posts: 8359


PostPosted: Sun Nov 16, 2014 12:04 am  Reply with quoteBack to top

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!
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bboy82
Experienced


Car: K04'd B5 S4 Saloon
Power: TBC
Engine code: AGB

Joined: 14 Mar 2011
Posts: 3260

Location: East Northants

PostPosted: Sun Nov 16, 2014 12:44 am Reply with quoteBack to top

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!


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Jakub
knowledgeable


Car: B5 S4

Joined: 16 Mar 2014
Posts: 324

Location: London

PostPosted: Sun Nov 16, 2014 12:55 am Reply with quoteBack to top

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...
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Fullraceken
knowledgeable


Car: B5 s4 avant
Power: Rs6 hybrid
Torque: Big

Joined: 11 Sep 2013
Posts: 300

Location: Somerset

PostPosted: Sun Nov 16, 2014 9:00 am Reply with quoteBack to top

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  

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benh999
knowledgeable


Car: RS4 B5
Power: 450
Torque: A plenty
Engine code: AZR

Joined: 22 Dec 2010
Posts: 620

Location: Rugby

PostPosted: Sun Nov 16, 2014 9:11 am Reply with quoteBack to top

More more

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Graham
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Joined: 20 Apr 2008
Posts: 8920


PostPosted: Sun Nov 16, 2014 9:48 am Reply with quoteBack to top

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


Car: Misano RS4 B5
Power: 504ps
Torque: 604nm

Joined: 03 Jul 2010
Posts: 4447

Location: Aberdeenshire

PostPosted: Sun Nov 16, 2014 9:52 am Reply with quoteBack to top

Cracking read so far!  Great effort!

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ScottR
Veteran


Car: B5 S4

Joined: 22 Apr 2008
Posts: 8359


PostPosted: Sun Nov 16, 2014 10:21 am Reply with quoteBack to top

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


Thanks Graham.
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Challice
Experienced


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

Joined: 05 Mar 2011
Posts: 3019

Location: Wiltshire

PostPosted: Sun Nov 16, 2014 10:46 am Reply with quoteBack to top

Love the blue calipers  
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Alps
Expert


Car: RS4 b5
Power: corrupts
Torque: is cheap

Joined: 06 May 2008
Posts: 4307

Location: London

PostPosted: Sun Nov 16, 2014 12:01 pm Reply with quoteBack to top

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



Joined: 20 Apr 2008
Posts: 1983


PostPosted: Sun Nov 16, 2014 12:13 pm Reply with quoteBack to top

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.
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ScottR
Veteran


Car: B5 S4

Joined: 22 Apr 2008
Posts: 8359


PostPosted: Sun Nov 16, 2014 12:23 pm Reply with quoteBack to top

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...
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DW
Skilled



Joined: 20 Apr 2008
Posts: 1983


PostPosted: Sun Nov 16, 2014 12:29 pm Reply with quoteBack to top

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


Car: Audi S4

Joined: 22 Mar 2010
Posts: 3686

Location: Barrow-in-Furness

PostPosted: Sun Nov 16, 2014 12:37 pm Reply with quoteBack to top

Good effort Scott. Love the write ups.

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99 Audi S4 (a love hate relationship)
96 VR6 Golf (sold)
91 Audi S2 (sold)
94 Subaru Impreza (sold)
94 VR6 Golf (sold)
92 Sierra cossy (went bang, sold)
91 Audi 90 20V (sold)
89 Ford Orion (scrapped)
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aidank1981
Experienced


Car: B5 S4
Power: 315
Torque: 375
Engine code: AGB

Joined: 16 Sep 2011
Posts: 2503

Location: shetland

PostPosted: Sun Nov 16, 2014 12:43 pm Reply with quoteBack to top

Hopefully this motivates us all! Great work!

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1999 T reg facelift 64k miles B6 wheels and brakes all round, KW variant 3's full turbo back 100 cell milltek non res AmD tuned aluminium mirrors.
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