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adam525i Reader
10/18/18 9:01 a.m.

For a second there I thought you were going with a metric wheel, 15" wheels doesn't seem like a bad solution compared to those. There are a lot of good looking options in that list, I don't think you'll go wrong with whatever you choose.

I love popping over into the classic motorsports section and seeing this thread has been updated.


teamilluminata HalfDork
10/18/18 9:58 a.m.

Thanks Adam,


You know, you could always "Favorite" the thread ;)

Bleed242 None
10/21/18 10:18 a.m.

This project is amazing. I've wanted to dothis with a coupe quattro for the last 20 years. You've inspired me to the point where I just might do it!

de80q Reader
10/26/18 3:34 a.m.
Bleed242 said:

This project is amazing. I've wanted to dothis with a coupe quattro for the last 20 years. You've inspired me to the point where I just might do it!

If you have one already, do it!  I had thought about converting my 80q, but then decided against it.  I like beating up all the Honda's in the area on the street too much haha.

teamilluminata HalfDork
11/9/18 9:56 a.m.

Installation was relatively simple as we kept all the hardware.

Then we remembered that we also have a broken reflector which we thought would be better used on this car rather than the pristine one that came off it as we are going to be wrapping it anyway a la Rothmans livery:

But how to fix the crack? It can be unsightly but has to be smooth as any hint of a crack will show up through the vinyl film. Fortunately one of our guys has a lot of experience with plastic adhesive and managed a nearly invisible repair.

Now we have to figure out how to wrap the black side pieces. As they have horizontal grooves running along their lengths they won't take vinyl very well. We could try to paint them but it might not match the vinyl and we'd be ruining a set. We have considered filling the grooves with body filler and sanding them flat. That would wrap easily but we'd still be ruining a set. Currently considering making new filler panels. Fortunately we don't have to decide for a while though.

More rear of the car projects. Another piece (two actually) that would be better stored in the car is the rear bulkhead. It comes in two parts: a lower and an upper. The upper part is essentially a parcel shelf as it is mostly horizontal but is definitely not flat. No parcels will be stored here. We think this will be just a test fit as it may be in and out a lot in the course of the build, though it will be going to paint with it fully installed. It will definitely need to come out to allow us to clean up the aperture edges. Looks like that was cut with a torch.

Both pieces clearly needed to go through the side window openings. The lower panel fell into place without much trouble.

But the upper one fought us hard. We even called the cage builder and the body shop; the last people to mess with it but they couldn't remember how they did it. At least we now had the confidence to know that it does fit so we continued to jiggle it around and look for a way in. This seemed like the way it wanted to go but it wouldn't slide any further back.

Eventually we sort of curved it as we slid it down the cage bars and then it fit nice and snug.

Now we have to get it out again!

Work continues on the dash, bit by bit. We bought an old rally computer that came off a Rothmans car in the middle east. It has no internal parts but we have another one that does and that may find its way into the car eventually. For now this one is easier to install.

Then we thought we'd have some fun.

We just need to repaint one of the 911s and get a Rothmans Quattro model (on order) and we'll have a perfect set!

While we seem to be working on the rear of the car we thought we'd throw in the fuel tank. It's big and takes up a lot of space on the parts shelf. What more rationalization do you need. Oh, we also want to see where the fuels lines exit the trunk area so we can figure out where to locate lines, pumps and filters etc.

It was a bit awkward to wrestle into location, but soon cooperated.

The fuel lines protrude through the trunk floor. Perhaps we can extended them through the lower rear bulkhead and mount the fuel pump/s in the cabin.

759NRNG SuperDork
11/10/18 11:08 a.m.

teamilluminata HalfDork
1/16/19 11:30 a.m.

Acquisitions and (no) Mergers

Another long gap between updates, sorry. We have been traveling and working a lot and then there was the holidays to contend with. Still, we did manage quite a few parts acquisitions but we didn’t get to merge much of them with the car.

Our long awaited 20V engine arrived late last year. Thanks to Marc of EFI Express for assembling it for us. It’s a AAN engine out of an S4 or something like that. Marc tested and resealed it, replaced the head gasket, water pump, timing belt etc. Chipped the ECU, stripped the wiring harness and included an S4 down pipe. Then packed it in this amazing box.

We feel we can have a more reliable 350hp out of this 20V than trying to make the 10V do the same.

We had an oversized grill badge 3D printed by our friend Brandon Horsch.

During our travels we picked up some warning lights and switches from England. We did get to “merge these with the dash.

The dash just needs fuse panels and Dzus fasteners now..

Blower cover from Europe.

We also acquired some works of art from a fellow Audi rally enthusiast in England and couldn’t resist mocking one up.

We have now made it back into the workshop and have been busy refurbishing various parts. Hopefully our next update will be more about mergers than acquisitions. Stay tuned.

teamilluminata HalfDork
2/6/19 9:15 a.m.

Rally Cars Need Heaters Too

We could have just wiped the dust of the heater box a bolted back in place but we are glad we took it apart as we found the heater core had been weeping or leaking. Besides, all the seals needed replacing and it was full of leaves inside.

We had also broken off a tab from the blower while removing it from the heater box so that needed to be glued back together.

The heater box consists of two halves held together by spring clips. It didn't take long to split it.

The leaky heater core and its replacement. These seem to have been used in every Audi, VW and Porsche made in the 80s so finding one was quite easy.

We broke a clip off the heater core lid but have already found a replacement on eBay. We'll pop that on after the dry build.

New seals and into the car with it and the cover we got from a fellow Quattro enthusiast.

It's nice to bolt things to the car. We get all warm and fuzzy inside, plus we'll be warm inside the car too.

We also took the opportunity to refinish our helper springs for the coilovers. Even though these have never been used most of the powder coating had already deteriorated. We decided to try Plasti-dip rather than re powder coating as this is way more flexible and will not crack. We will see how well that works one day in the future.

Wipers, tie rods and heater are next up. Don’t miss it.

teamilluminata HalfDork
2/28/19 1:19 p.m.


Now we had the heater in we thought it a good idea to install some of the ducting to spread that heat where it might be needed. The foot wells heat comes right out of the side of the heater box so we don’t have to deal with that, and the center and side vents are fed from flexible pipes so we can figure those out later. But the windshield defrost blows through the firewall bulkhead and into a distribution manifold that used to be part of the molded dash pad. Fortunately we hadn’t managed to throw the dash pad away.

This is the plastic distribution manifold on the underside of the dash pad.

From what we gleaned looking at hundreds of restoration pictures is that you cut the dash pad to leave just this front area containing the manifold and vents then remove all the molded on dash pad foam from the top and bolt it back into place. Of course our manifold was cracked so we had to disassemble the thing.

This is how the manifold interfaces with the bulkhead/dash tube once it’s all put back together. You can see the central feed from the heater box below the dash tube. 

Next we removed the excess dash pad material with a cutoff wheel and set about cleaning it up.

We covered up some excess holes that were previously blocked and painted it and the vents satin black.

Then we set about fixing the plastic manifold.

While the glue was setting up we riveted the vents back into place.

Then we applied some sealant before riveting the two parts back together.

And then popped it into place.

For some reason this was one of the most satisfying projects we have tackled so far. Next time we’ll restore and install the washer bottle and coolant reservoir. Maybe not so satisfying.

teamilluminata HalfDork
3/6/19 3:00 p.m.

Cracking on with engine bay stuff we installed the clutch master cylinder. Remember, we have an 20V AAN engine just itching to try on this engine bay for size so we want to get as much engine bay stuff figured out before it crawls in there.

Not wanting to lose our bottle before the engine fit we also tested and installed the coolant reservoir. We rigged up this pressure test to see if it would hold 1.35 bar:

The reservoir didn’t leak but the cap let go at about 1.2 bar. We tried our cap from the 85 URQ and it held. We are going to need a new cap.

We cleaned it as best as we could and bolted it in place along with the washer bottle.

We should’ve thought about this earlier but after crawling under the front bumper all afternoon we decide it was time to take the front bumper and bumper bar off the car. Duh!

We now have a walk-in Quattro.

We know, not very exciting stuff but next we are going to work on the very trick twin master brake system with bias bar that we got from England! Riveting stuff! No, actually it bolts in.

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