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Audi UR Quattro Rally Build

  #51  
Old 02-28-2019, 11:43 AM
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Location: Birmingham, MI
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Acquisitions and (no) Mergers

Another long gap between updates, sorry. We have been travelling 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 warninig 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.
 
  #52  
Old 02-28-2019, 11:43 AM
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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.

 
  #53  
Old 02-28-2019, 11:44 AM
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DEFROST MANIFOLD

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.

 

Last edited by team illuminata; 02-28-2019 at 02:04 PM. Reason: broken image
  #54  
Old 03-06-2019, 03:50 PM
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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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