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 Never Say Never Again - One DIY project too far... View next topic
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Car: B5 S4

Joined: 22 Apr 2008
Posts: 8501

PostPosted: Fri May 15, 2015 9:12 am  Reply with quoteBack to top

More post-work fun

The weekend ahead was the target date.  Yet again I had a deadline - wifey's friend's wedding down near Worcester.  It was only going to be a 250+ mile round trip, but for added pressure we were taking down one of her friends... the AA was not going to be an option!  

Booked the car in with Awesome GTI for a 4 wheel alignment on the Friday.  No excuses, it had to be ready for then!

Due to the forthcoming nuptials, I was going to have to put in some hours after work every night before then.  I drew up a list.  Longer than I wished it was!

And straight away I found things which weren't on the list.  In my haste to get the engine back in the engine hole, I had managed to drop one mount into the wrong hole!

Got the driveshafts and prop hooked up.  Lovely new bolts.

Needed to tidy up the oil cooler pipework and make sure everything looked pretty.

Wheels were cleaned.  Really cleaned!

Got the front panel sorted.  Took a fair while to manoeuvre the oil cooler pipes into the correct orientation (because i'm using an internally tapped adaptor in place of the corroded external thread, this pushes the hardline out by a few cm).  Was a bit of a pain, but went together eventually.  I was just glad to finally have it all hooked up.

And being sad, I got upset at the grimyness of the bonnet latch.  So that also got cleaned and regreased.

Exhaust was fitted, everything underneath the car checked and double checked.  Finally... my time under the car was at an end!!!

Rear brakes... what a faff!  I was having a nightmare trying to get the handbrake cables on.  After spending what seemed like forever trying to yank them through enough to get them on, I finally realised that, yes...  I had left the frigging handbrake lever pulled up!  

Felt like a tool, but was glad of the victory, no matter how small.

I then had trouble getting the brake pads in.

It turns out, you actually CAN have too much Hammerite!  Just needed to scrape a tiny bit off where the brake pads locate, and it all slid nice and smoothly.

Only a couple more tasks before it was ready for action.

Fitted the splitter.  Was using Hercules for the strong work, but imagining the sort of force which is trying to blow the splitter off the bottom of the bumper when driving at Mach1 did make me go for a belt and braces approach.  I used a small amount of Sikaflex to bond some parts of the splitter to the bumper as well as the rivets.  Left it overnight to cure.

And used a highly accurate method to hold the curve of the ends whilst I drilled and rivetted.

And finally onto the amusing part of this instalment.  The front calipers I had acquired had just been refurbed, but for some odd reason the bleed nipples were pretty crappy and rounded, so I bought some lovely new replacements.  The existing nipples seemed to be an odd size, so I got a crappy old imperial spanner and used my Dremmel to open it up a bit.  Nope, too small still.  A bit more Dremmel action, and repeat.

When I finally got the spanner to the right size so it went over the nipple nicely, I got it out.  Upon placing the spanner down next to my 8mm spanner, I realised what I had done...

Yep... I had ground out an imperial spanner to near enough precisely 8mm!  What a spanner!!!

The new nipple had a 10mm 'nut' and looks far less likely to round off than the original.

With everything hooked up, I filled the fluids, connected the battery and fired up the car.  Turned it over a few times with amps disconnected and fuel pump fuse pulled to get some oil into the top end.  Started first time, no drama.  Got the PAS pump bled whilst the engine got up to temp, then as I was on all 4 axle stands, whacked it into gear.  Put it into 2nd and took it up to about 3k to get the gearbox oil pumping through the rad.   Engine off, fluid levels checked, all sorted.  

I was going to make it!!!!
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Car: B5 S4

Joined: 22 Apr 2008
Posts: 8501

PostPosted: Wed May 20, 2015 9:16 am Reply with quoteBack to top

The End (again)

Only a few small jobs left to get it roadworthy.  

Rear Brakes were fully fitted ready for bleeding.

Bleeding was a real pain due to the system having been emptied out completely.  I ended up putting two litres in to try and get rid of all the air, but I still had virtually no pedal.  Jimbo came to the rescue, suggesting it was probably air trapped in the ABS pump.  Sure enough, connected up my pressure bleeder at about 12psi, cracked open the first union on the top of the ABS pump and there was plenty of air released.  Ran the ABS bleed cycle through Vagcom after that as well and ended up with working brakes!

Seemed a waste of clean fluid, although it's looking much nicer than the gravy that came out!

Before putting the front bumper on, I somehow managed to snap the ambient temp sensor clean off!  Thankfully I had one from the old car.

Dropping the car back onto 4 wheels after all this time was exceptionally satisfying.

And I was quite happy with the first glimpse of the front splitter fitted.

I even quite liked the look with no headlights, and have at times toyed with the idea of getting some Lamin-x tints, but to this day have never got around to it.

Took the car for a cheeky spin around the block looking like this.  

Well, I had to make sure I wasn't leaving fluids behind again like the first shakedown!  

Remembered at this point that one of my headlights had stopped working before the teardown began, so thought i'd sort that before heading over to Awesome for the alignment.  Turns out the wiring for the cheap Chinese HID kit i'd been using for years had finally given up the ghost.  Looks like they had used tin foil instead of copper in their wires!  Had a few replacements knocking about, so that was a nice easy fix (fast forward another few months and I ended up fitting OEM again).

That first decent drive after a build like this is always a nervous one for the DIY'er.  

But I enjoyed every minute of it.  The car was running very nicely indeed.  It went well, it stopped well, it changed gear very well.  After the first 30 mins of driving along in paranoid silence, listening out for anything untoward, I even tested the stereo still worked.  It was a great success.

Got to Awesome for the alignment and asked them to check over all the bolts, as I had been getting a clunk from the front end when turning over a bump.  They found more than one bolt not torqued up correctly.  

Still, when they took me over to the car to show me which ones, it gave me the opportunity to check for leaks (none! ) and take some pics...   All my graft was worth it!

One thing I did notice was the underside of the pass intercooler pressing against the bottom of the (not yet aligned) front bumper.  I was going to have to address the IC mounting again at some point.

Alignment was done, bolts were torqued and clunk was now gone!

Leaving Awesome, I headed over to see Rick @ Unicorn.  Up until now I had been driving on the map from Blue Thunder, which had been fitted with an RS4 MAF and Y-pipe, APR Bipipe and Water/Meth Injection.  I wanted the map tweaked to ensure it was running safe on the lesser spec of New Thunder.  We spent a good couple of hours tweaking, and it was safe to say that the car got a proper post-build shakedown, I can tell thee!  

I left Rick's very happy with the smooth power delivery.  Sadly not as much punch as the old car, but I had specifically asked for an 'all out' map on that one, so to be expected.  Very satisfied indeed.

The following night I was able to give the car a good clean.  It had to look presentable turning up to a wedding.  Given there had been a little bit of angle grinding and some dremmel cutting action in the vicinity, and I could see a few small tears of rusty water marks on the bonnet as a result, I turned to a new product in my cleaning arsenal - Iron max.  This stuff is supposed to dissolve small iron particles such as brake dust and 'fallout'.  Turns purple when it reacts with the stuff it's dissolving.  It had a lot to clean...

A little cheeky pic of the rear wheels/brakes once cleaned

And in conclusion to the 2nd leg of this epic project, one very satisfying shot taken on the way to the wedding.  I really like this photo.

As with any SMART project, one needs to assess the outcome against the requirements.  Let's see how I got on with that list from Page 1 - the list I had originally intended to COMPLETE in 10 days...  
Project Requirements wrote:

Engine Pull Done... and Double Done!!!!  Never to be repeated again.  (although I Never say Never now! )
Fit K04's and pipework Done
Fit RS4 Intercoolers Done - tweaking needed to pass side fitment for bumper to fit flush
Fit Injectors Done - Took far too long due to torn injector seals - Mikey-S to the rescue!
Fit Bosch 044 fuel pump Done
Fit lovely new 'Liquorice Allsorts' Gearbox (beats the chocolate gearboxes in most S4's! ) Done - Stupid aftermarket clutch meant this needed to be done twice!
Fit Downpipes Done
F-Hose and N249 delete Done - still not sure if I will reinstate the N249 though...
Fit new Rocker Cover Gaskets Done - twice due to using wrong sealant the first time!
Spark Plugs Done
Replace front subframe Done
Replace rear arms Done
Fit B5 RS4 brakes up front Done
Fit Trig's B6 setup to the rear Done
Fit Exhaust Done
Fit RS4 Oil Cooler Done
Fit RS4 engine mounts + 034 Tranny mounts  + 034 Snub Mount Done
Replace front wings (orginals bubbling to hell) Not started
Replace steering wheel Done
Fit cluster with repaired DIS Done

And on top of that list, I had also managed to:
Other stuff I ended up doing which I wasn't expecting wrote:

Replace Spider Hose with DIY job
Refurb Rear Subframe + Bushes
Remove Refurbed Front Subframe and fit with new bushes
Clean up (+ paint if necessary) loads of various bits
Fit Short Shifter
A lot of pipework faffing for Oil Cooler
Fix Headlight

So aside from the front wings, looks like I was done.  Although it had taken me nearly 5 months to get that far.  And what had been planned as a virtually zero budget build, became a rather expensive 'modstoration'.  

Overall, i'd say a big success.  I hope you've enjoyed the journey with me.

But... it was not over yet...
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Joined: 22 Sep 2012
Posts: 1707

PostPosted: Wed May 20, 2015 1:02 pm Reply with quoteBack to top

Good work my man, you've done a grand job so far.. and your still in one piece! bonus.

Its looking really well... Can i just ask. What on earth do you like about that picture? (apart from your car being in it)

Was an S4. That became an S4/RS4 Widebody now its turning into an RS4...
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Car: B5 S4

Joined: 22 Apr 2008
Posts: 8501

PostPosted: Wed May 20, 2015 1:30 pm Reply with quoteBack to top

It's the angle of the dangle Kent. Just think it looks like a nice clean car there. It's not the exotic location!
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Joined: 22 Sep 2012
Posts: 1707

PostPosted: Wed May 20, 2015 1:33 pm Reply with quoteBack to top

Its all about the angle of dangle Scott. And I must say you are correct... you are hanging well in that shot.

Was an S4. That became an S4/RS4 Widebody now its turning into an RS4...
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Car: B5 S4

Joined: 22 Apr 2008
Posts: 8501

PostPosted: Wed May 20, 2015 2:28 pm Reply with quoteBack to top

Dressed to the left in that pic.
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Car: Misano RS4 B5
Power: 504ps
Torque: 604nm

Joined: 03 Jul 2010
Posts: 4619

Location: Aberdeenshire

PostPosted: Wed May 20, 2015 3:13 pm Reply with quoteBack to top

Great effort Scott!  Car looks really well!  Must be nice knowing that it is in such good order too!  Enjoy!

Misano B5 RS4 - Now weekend runner
Pearl white 20v ur quattro - mmmm!
Audi 80 B4 avant alpine white! Beast haha
Daily mk5 gti
S3 8l Imola! - Sold
Red S3 - Sold
Black 1.9TDI A3 - Sold
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Car: 2002 B5 RS4
Power: 430 bhp
Torque: Whatever
Engine code: BHP

Joined: 07 Oct 2012
Posts: 12190

Location: In front of you, lol'ing

PostPosted: Wed May 20, 2015 5:09 pm Reply with quoteBack to top

Awesome Scott.

I bet the write ups took nearly as long as the work,


this is one of the pics you can't stop looking at..

Reckon it was nice to be able to stand up underneath your car for a change rather than laying on your back?

Fancy a new lifetime residual revenue stream?

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

Joined: 22 Dec 2010
Posts: 621

Location: Rugby

PostPosted: Sun May 31, 2015 9:38 pm Reply with quoteBack to top

absolutely stunning S4.  B6 rims are killing it!!!

You built a time machine...... Out of a Delorean???!!
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Engine code: ASJ

Joined: 20 Feb 2014
Posts: 315

Location: Canberra, Australia

PostPosted: Mon Jun 01, 2015 1:35 am Reply with quoteBack to top

Great job, both the spanner twirling and the writing. I'll bet there were days when I was enjoying it more than you. Top job, and now I have to look back and read about your previous exploits.
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Car: B5 S4
Power: 315
Torque: 375
Engine code: AGB

Joined: 16 Sep 2011
Posts: 2603

Location: shetland

PostPosted: Fri Jul 29, 2016 4:13 am Reply with quoteBack to top

benh999 wrote:
absolutely stunning S4. B6 rims are killing it!!!

agreed! what spacers are you running? i'm a bit lost with wheels just now!

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

Joined: 05 Mar 2011
Posts: 3069

Location: Wiltshire

PostPosted: Fri Jul 29, 2016 6:55 am Reply with quoteBack to top

Looks spot on, under side looks great I'd like to get mine that tidy.

Splitter looks good too I'm still not sure weather to pit one on mine
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Car: B5 S4

Joined: 22 Apr 2008
Posts: 8501

PostPosted: Mon Aug 01, 2016 7:54 pm Reply with quoteBack to top

Wow, what a thread resurrection!

Aidan, I've got 10mm at the back and I think 8mm up front. Could be 10's all round though.
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Car: Noggy s4 b5
Power: 334
Torque: 440

Joined: 09 Nov 2015
Posts: 358

Location: Salford/manchester

PostPosted: Mon Aug 01, 2016 10:44 pm Reply with quoteBack to top

Stunning mate how much did awsome charge for the alignment
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Car: B5 S4

Joined: 22 Apr 2008
Posts: 8501

PostPosted: Tue Aug 02, 2016 11:47 am Reply with quoteBack to top

No idea. And presumably their prices might have gone up since it was there in 2014!

Was back in a local place for realignment last June after some more build action. Really should update this thread!
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