Another project

  1. zeppelin builder

    zeppelin builder Member

    Messages:
    1,162
    Location:
    peoples republic of scotland
    Got the clutch 20180922_164109.jpg unstuck and gave it a good run up the stubble field like a big organic wire brush
    Its still in good nick
    Next I'm do away with the sunroof and start working on it proper
    Volvo t5 power soon
     
    Parm, Rannsachair, Burdekin and 12 others like this.
  2. Ruffian Member

    Messages:
    1,671
    Location:
    Devon UK
    Awesome another audi coupe quattro owner.
    Is this a 2.2 narrow body non turbo also??

    If you do end up removing any bits for upgrades please bare me in mind
     
  3. zeppelin builder

    zeppelin builder Member

    Messages:
    1,162
    Location:
    peoples republic of scotland
    Yes it's a narrow one fitted with a later 2.3 mill was off the road 15 years .it had been driven over something that had pushed the engine and box up hand broke the mounts and alternator boss on the 2.2 block
    The owner welded the casting with mig but it was part of the main gallery so it leaked oil badly hand he literally threw a later avant 2.3 engine in the air metering unit was just hanging there etc
    I made an ally Airbox and sorted out a few bugs and ran it for a couple of years it's a weapon in snow and mud
    When I got it it still had the zinc plating on most of the fasteners I think it had done 32000miles the sun roof has got to go as it was siliconed up shut all the main panels were in great nick under the plastic covers
    The only rusty was on the nearside wing
    A pop on cheapie replacement
    I won't be making it wide or shortening it
    Just a few things like the Volvo t5 mill hand the later gearbox and diffs from an avant Quattro I used to have
    I've already made a hybrid clutch ,Volvo flywheel with audi pressure plate and clutch plate
    I need to make up a spigot bush and .make a plate for the bellhousing
    With the current engine it's reasonably pokey
    And sounds sweet
    I have a few bits let me know what you need
     
    fixerupper, indy4x, Gwil and 4 others like this.
  4. Ruffian Member

    Messages:
    1,671
    Location:
    Devon UK
    Sounds like someone had some fun in yours then.

    Managed to do a deal on our one a few years back. Barn find been off the road for quite a while. Needs referb but not too bad.

    Always after spares.
     
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    Parm and 8ob like this.
  5. slim_boy_fat

    slim_boy_fat Forum Supporter

    I looked at an UR Quattro many years ago, with a view to getting it [Tornado red, iirc the colour was called].

    Luckily I had taken a pal with me and when he saw what I was intending he said "Come on, it's time we left".
    When I asked why [I was really keen on the car] his reply was "You'll just kill yourself with that thing".

    Seems he knows me better than I thought, on reflection, he was possibly right.........:rolleyes:
     
    fixerupper, Greeves246 and Kayos like this.
  6. zeppelin builder

    zeppelin builder Member

    Messages:
    1,162
    Location:
    peoples republic of scotland
    The roads up your way are very dangerous
    Lots of nutters with fast cars and red deer everywhere
     
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  7. slim_boy_fat

    slim_boy_fat Forum Supporter

    More so since the inception of the NC500, which has been a victim of its own success. :rolleyes:
     
  8. zeppelin builder

    zeppelin builder Member

    Messages:
    1,162
    Location:
    peoples republic of scotland
    bit more work done on old audi
    removed rotting roof panel and leaky sunroof and made and fitted a,1.2 mm zintec panel no more leaks ,also made a centering mandrel to help mate the audi box to the t5r volvo mill .il make a plate to match them up next them machine a hybrid flywheel well its a start at last 20181214_164413.jpg 20181111_115040.jpg 20181214_164413.jpg 20181214_164420.jpg 20181214_164400.jpg
    20181111_115040.jpg
     
    Hood and Ruffian like this.
  9. zeppelin builder

    zeppelin builder Member

    Messages:
    1,162
    Location:
    peoples republic of scotland
    got the gearbox plonked on top and the shaft centered ,chopped it off roughly
    out side slightly big to allow for grinding .
    il drill and tap the plate fit a couple of dowels to locate it to the gearbox side then il drop it on top of the engine again
    il turn up punches to fit the through holes and mark through .for the blind holes ll use grub screws turned to a point and just protruding so after i have the initial bolts wit dowels fitted all i have to is whack the plate and il get the blind hole centres
    good old redneck technology ! once its done i can fit the flywheel and mark and cut out the centre "the shaded area "
    and mark out for the volvo starter 20181215_144659.jpg 20181215_144712.jpg 20181215_153016.jpg 20181215_144659.jpg 20181215_144712.jpg 20181215_153016.jpg
     
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  10. zeppelin builder

    zeppelin builder Member

    Messages:
    1,162
    Location:
    peoples republic of scotland
    almost finished the conversion plate pattern just dowels for the gearbox now and remove a bit bell housing to clear starter had to add bits back on that id cut off was a bit hasty wi the plasma theres a hundred things to consider when mix n matching ,an A6 2.8 clutch plate after much head scratchin will
    not foul the volvo flywheel .
    a few more holes to drill through the plate
    once the gearbox is centred again!
    plenty fixings on the engine side and dowels

    20190102_164723.jpg 20190102_164723.jpg 20190102_164827.jpg 20190102_164827.jpg
     
  11. zeppelin builder

    zeppelin builder Member

    Messages:
    1,162
    Location:
    peoples republic of scotland
    heres todays progress relocated and built up a main mounting lug ,juust built up against the plain shank of the bolt with weld metal after fusing either side ,its worth moving the bolt now and then this breaks any bond , knock the bolt out and a quick file up and voila new lug with spot on location

    its so quick with mig and not so fussy about cleaning as tig 20190103_121117.jpg 20190103_121756.jpg 20190103_123736.jpg
     
  12. zeppelin builder

    zeppelin builder Member

    Messages:
    1,162
    Location:
    peoples republic of scotland

    here is some more progress plate almost done been altogether and starter positioned
    had to source audi a6 clutch plate with a raised centre , machined centre boss and fitted oilite bush . next session is to fit the mongrel pressure plate bolt it all together and plumb it up to a spare pedal/ slave cylinder and check it works and the clutch disengages , ihad to use a 12mm plate as the volvo ring gear is bigger diameter than the audi bell housing ,also had to sand the inside of the bell housing to miss the timing segments
    20190111_163539.jpg 20190111_163527.jpg 20190111_163609.jpg
     
    Rannsachair, Hood and eLuSiVeMiTe like this.
  13. zeppelin builder

    zeppelin builder Member

    Messages:
    1,162
    Location:
    peoples republic of scotland
    heres the sump now modified ,it needed a chunk removed to clear the x member
    Tonight i laid in a bit of 5mm ali plate and tig welded it ,its now clamped down and being straightened after a good post weld roasting
    tommorow i will spray the inside with dye penetrant and look for any minor weeps

    was realy surprised with the thickness of the volvo sump its only around 2.5 mm
    deffo need a sump gaurd 20190205_184205.jpg 20190205_184111.jpg 20190205_184059.jpg
     
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  14. zeppelin builder

    zeppelin builder Member

    Messages:
    1,162
    Location:
    peoples republic of scotland
    here is another step forward in the jigsaw puzzle i had to weld 2xsplined centres together to get sufficient length and a good driving spline area i found the old clutch plate today and removed the centre ,prepped it as you would a pipe weld slid both components on the gear box input shaft for alignment tacked them carefully at 4 points wih earth on the outside so it didnt earth on the splines , did a hot first pass at 100 amps then did a second pass at 75 anps with the assembly off the shaft , when the weld cooled off it had shrunk a few thou and was very tight on the shaft ,no problem just carefully hammered the capping run and that stretched the metal to give a nice sliding fit
    the bosses were not very hard either so it was relatively easy
    i used filarc pz 6513 1.6 mm this has nickel content so gives a strong tough weld
     
  15. zeppelin builder

    zeppelin builder Member

    Messages:
    1,162
    Location:
    peoples republic of scotland
    oops heres the photo 20190325_162820.jpg
     
    Morrisman and Hood like this.
  16. zeppelin builder

    zeppelin builder Member

    Messages:
    1,162
    Location:
    peoples republic of scotland
    started making the inlet manifold today
    cut up the original plenum and shaped up a bit of 50mm id tube and welded it
    ive retained the facility to use the injectors to inject water and or methanol but the main fueling will be a Su hs8 blown through to keep things simple as i know carburation inside out

    holes were cut with a holesaw and manifold runners shaped next everything cleaned wit a carbide burr then tacked up and welded . the flanges being bridged obviated clamping it down to a surface whilst welding .Additionaly i managed to seal weld the centre and two outer ports through the centre hole where the carb stub be mounted

    next end plugs ,carb stub ,servo and boost connections 20190415_164643.jpg
    20190415_154413.jpg 20190415_164943.jpg 20190415_153039.jpg 20190415_154413.jpg
     
  17. zeppelin builder

    zeppelin builder Member

    Messages:
    1,162
    Location:
    peoples republic of scotland
    another bit progress on the manifold,profiled pipe ,made flange then welded em up ,put plenty weld on it so i can radius the corner with a,long carbide burr 20190416_125648.jpg 20190416_124254.jpg
    20190416_125648.jpg
     
  18. stuvy

    stuvy Member

    I had one of these a few years back made a few quid selling it on

    My dad had a UR as a company car and I loved the noise it made. Was so disappointed to drive one of my own as being 8 when he had his it was so much faster!

    I still love the boot release in the drivers b post
     
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  19. zeppelin builder

    zeppelin builder Member

    Messages:
    1,162
    Location:
    peoples republic of scotland
    couldnt find that bloody lever when i first got it ,mines should be nippy wi the volvo power when im finished
    manifold nearly finished 20190416_183551.jpg 20190416_183551.jpg 20190416_202456.jpg
     
    fixerupper and slim_boy_fat like this.
  20. stuvy

    stuvy Member

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