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-   -   Project B5 RS4 Sedan. (https://www.audiforums.com/forum/b5-models-69/project-b5-rs4-sedan-106358/)

Siena Jun 29, 2008 05:57 AM

Project B5 RS4 Sedan.
 
Just thought I would post this on here - the full conversion, parts bought, as well as the surgery process.

As many know, power is not coming courtesy of a 2,671cc Biturbo V6, (though that was my original plan) but an S8 4,172cc V8, initially in n/a form.[/align]
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Siena Jun 29, 2008 06:02 AM

RE: Project B5 RS4 Sedan.
 
4 Attachment(s)
First of was finding a base car, it had to be fairly cheap, fairly sound mechanically, all running gear was going to be replaced anyway.

Bodywork wasn't important either, as all panels bar the roof were going to be replaced with genuine RS4 items.

What was important though, was the drive - it had to be quattro, no front track would handle the power I had planned...

So, I located a '96 A4 2,6L V6 QS, for the sum of £500, with about 200,000 miles on the odometer, and her fair share of battle scars.

As collected...

Attachment 54678
Attachment 54679
Attachment 54680
Attachment 54679

Siena Jun 29, 2008 06:08 AM

RE: Project B5 RS4 Sedan.
 
4 Attachment(s)
I drove her stock, then began the painstaking task of sourcing genuine RS4 goodies.

After trawling through ebay.de, it became fairly obvious that people parting RS4's in Germany wanted way too much for the parts, and of course, shipping would be a killer.
So, I decided to buy new.

I first ordered the front fenders, rear quarters, and the rear doors.

Front fenders...

Attachment 54674
Attachment 54675

Rear doors...

Attachment 54676

Rear quarters...

Attachment 54677

Siena Jun 29, 2008 06:18 AM

RE: Project B5 RS4 Sedan.
 
9 Attachment(s)
Next, was the ordering of the RS4 front bumper, Euro S4 rear bumper, RS4 grille, RS4 sideskirts.

RS4 front bumper...

Attachment 54665
Attachment 54666

Euro S4 rear bumper...

Attachment 54667
Attachment 54668

RS4 sideskirts...

Attachment 54669

RS4 grille...

Attachment 54670

RS4 bumper grilles...

Attachment 54671

RS4 foglamps...

Attachment 54672

RS4 bumper irons, they are longer than stock A4...

Attachment 54673


Siena Jun 29, 2008 06:25 AM

RE: Project B5 RS4 Sedan.
 
4 Attachment(s)
Now, the RS4 front doors only differ from facelift ones, in that they lack mid and lower trims.

So, I decided to buy these used, all that they'd need then, would be to have the 6 little holes welded up, and the lower trim studs ground off.

I bought these...

Attachment 54661
Attachment 54662

I also wanted the Euro facelift trunk lid, so bought from the same B5 that liberated its front doors...

Attachment 54663
Attachment 54664

I wasn not going to just slap the trunk on as it was, I wanted a subtle B6-style modification, but more of that later.

Siena Jun 29, 2008 06:36 AM

RE: Project B5 RS4 Sedan.
 
7 Attachment(s)
Then came RS4 cast aluminium mirrors...

Attachment 54654
Attachment 54655

Then RS4 one-piece xenon headlamps...

Attachment 54656
Attachment 54657

I bought A4 facelift rear tails...

Attachment 54658

And matching A4 facelift rear bulb holders...

Attachment 54659

RS4 front clip came next...

Attachment 54660


Siena Jun 29, 2008 06:43 AM

RE: Project B5 RS4 Sedan.
 
6 Attachment(s)
My kitchen was gradually filling up with RS4 parts.

Next were RS4 plastic wheel arch liners, left and right, rear...

Attachment 54648
Attachment 54649

Then RS4 plastic wheel arch liners, left and right, front...

Attachment 54650

Then RS4 gas tank flap...

Attachment 54651

I then realised that the RS4 MUST have wider rear wheel arch wells, to meet the wider arches.

So, I ordered these...

Attachment 54652
Attachment 54653

Siena Jun 29, 2008 06:50 AM

RE: Project B5 RS4 Sedan.
 
6 Attachment(s)
Then came the little bits and pieces, that are easy to over look.

B7 aero wiper arms and blades...

Attachment 54642
Attachment 54643

RS4 side repeaters...

Attachment 54644

RS4 headlamp washer covers...

Attachment 54645

RS4 headlamp washer pump...

Attachment 54646

RS4 headlamp washer bottle...

Attachment 54647

Siena Jun 29, 2008 07:00 AM

RE: Project B5 RS4 Sedan.
 
9 Attachment(s)
As I previously mentioned, I wanted to subtly modify my Euro facelift B5 trunk, so this happened...

Attachment 54633
Attachment 54634

My base car had over 200,000 miles under her belt, so it was obvious the suspension would be shot to hell.

I purchased -30mm Eibach Sport Springs, designed for the heavier RS4. It would lower my car less, but as I planned a larger, heavier engine and 6-speed tranny from the onset, I allowed for that.

Eibach springs...

Attachment 54635
Attachment 54636

Then RS4 Bilstein Sport Dampers, ordered from my local Audi dealership...

Attachment 54637
Attachment 54638

I also ordered the front lower arms...

Attachment 54639
Attachment 54640

...And a complete set of rear bushes...

Attachment 54641

Siena Jun 29, 2008 07:05 AM

RE: Project B5 RS4 Sedan.
 
4 Attachment(s)
I then settled on my wheels - BBS RX II's splits, in 8,5"x18" ET 20, with Dunlop Sport 9000 rubber, in 255/35x18, the correct dimensions for an RS4.

I ordered them, and they turned up from Germany 2 weeks later...

Attachment 54629
Attachment 54630
Attachment 54631
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