team illuminata

I didn't test the headlight relay kit today as I thought better of it. With so many wires detached from there things I didn't think it a good idea to introduce some live electrons. I did put back the lower console hiding the relays etc. and lubed the hood/bonnet pull handle so it no longer makes that awful noise.

What I next was take stock of what's left to do and what I need to do it. I'm actually close to the point where I will be stopped for lack of parts, some of them apparently hard to find. Here's what's still to do:

28 Refurbish CIS
29 Refurbish hydraulic system
31 Refurbish front struts tops, bellows
32 Install down pipe and turbo
33 Engine Oil
34 Transmission oil
35 Compression test
36 Attach sub-frame to transmission
37 Torque crank bolt
38 Clutch slave cylinder line
39 Install engine, trans, sub frame
40 Reconnect ancillaries
41 Bleed brakes
42 Hydraulic fluid
43 Fire up
44 Test drive
45 Alignment


and what I'm still missing:

CIS vacuum lines and god knows what else
Hydraulic lines, being remade by a friend
Strut Bellows 2 431412135
clutch slave cylinder hose 1 431721465 NLA
subframe bushings rear 2 857199419B discontinued
belt alternator 1 055903137G 9.5x850
front brake line 2 433837400A

any suggestions on where to get this stuff? Would prefer original Audi.

team illuminata

As I'm starting to run out of chronologically logical tasks I'm going to be jumping around a bit. First such worm hole leap: sub-frame bushings. Not all four though, just the front two. The rears are NLA and I haven't sourced an alternative yet. So here we go.....






Drill




Cut




Pry




Succeed




Sleeve still in




More cut and pry




Squeeze




Fail




Succeed a bit then fail




Win




Repeat.

team illuminata

After lots of back and forth and soul searching (as well as part searching) we made some part-ial progress:

CIS vacuum lines and god knows what else
I printed out four parts diagrams from vagpart.com and marched them up to the shop with the plan that I would go through each one and highlight (with a hiliter) everything that I wanted to replace. This would mostly be vacuum lines and clamps but there are quite a few different sizes and types so I wanted to make sure I got the right ones and didn't miss any. Well, guess what? I could barley even match the diagrams to my car! It's like the car and the diagrams are for two different cars, not even the same manufacturer. I found one common part; a bubble shaped vacuum bottle, and followed it's line back into the engine bay and at the first connector it departed from the parts diagram completely! We are going to have to rethink this approach. This is one of four vacuum line diagrams vs the real world.



Hydraulic lines, being remade by a friend
Still waiting on these. Might be a while.

Strut Bellows 2 431412135
I found they match a Porsche 944 part so ordered a pair from one of our customers: Pelican Parts. Will see next week if Porsche and Audi were on the same planet back in the 80s.

clutch slave cylinder hose 1 431721465 NLA
I got close but quit. I found an ATE hose that matched but it proved to be a unicorn. Couldn't find one anywhere. Then I got a quote from our local fancy custom line shop for braided stainless made from my original fittings but baulked at the price ($140) and the lack of originality, then decided the original one was in good enough shape and installed it on the clutch cylinder.

subframe bushings rear 2 857199419B discontinued
A friend pointed out that I could used the Audi 80 M12 version with a 10mm sleeve so I went on a quest for those. They proved only marginally less rare than what I need so I orderded two proper ones from Audi Tradition. They have to be shipped to my friend in Germany and then to me so probably 2017 before I see them LOL

belt alternator 1 055903137G 9.5x850
This can wait. I'm tired.

front brake line 2 433837400A
Hours more research and all I could find were aftermarket braided stainless or some really inexspensive rubber ones from Centric. I've ordered both. The centric ones look like the real deal apart from not having the rubber dongles on though it does have two mounting grommets. The OE mounting grommet should slide off over the ends if one of these doesn't work but there's no way the big rubber dongles will. I have a few spares from our 83 so will cut one and see if it is possible to glue them back together over the Centric lines.

team illuminata

Finally got chance to install the rear subframe bushings. To be fair I did have to wait for them to come from Germany. I might havre to wait for another one now. Read on.........

Easily removed the old bushings and cleaned up the holes.


But my previous method of pressing them in failed



So got the press out but that didn't help




Now the bushing is all squished




It seems that a) these bushing won't squeeze into a hole the same diameter as the body and b) why did the front ones press in so easily?

wego0002

Paul,

call me and I tell you how to do this the right way.
Ciao
Werner

paredding

On my similar rebuild - I used braided Goodrich brake hoses - far superior to rubber.

On the bushes, I used the Powerflex / Superflex options. Easier to fit.

team illuminata

This didn't help



But this did

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Now I just need to order another one from Germany

team illuminata

It's been over a month since I updated this thread so, even though not much has happened I will document it anyway. Actually, looking at my Flickr album there's been quite a lot of little incremental progress

First off I received a new and spare bushing from Germany and wasted no time pressing the last one home. You just have to make sure it is being pressed true then squeeze with confidence, after first lubing the sh*t out of it.

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr


Then I replace the front strut bellows which arrived the same day as the bushings. Incidentally these are for a Porsche 944! Same part though.

image by Team Illuminata Motorsport, on Flickr


More bloody squeezing. GGRRR

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr


Then I installed the turbo, manifold and down pipe.

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr


Need to find a suitable hanger for here.

image by Team Illuminata Motorsport, on Flickr


This stainless steel beauty from Vibrant should do the trick.

image by Team Illuminata Motorsport, on Flickr


Next job is to attache the subframe then it's ready to go back in the engine bay. However, the engine bay is not yet ready to accept it as I still need to reinstall the steering rack and refurbish the CIS system. I may reuse the existing hydraulic lines as my supplier's are not in production yet and I want to be driving this in April.

team illuminata

I went through my parts bin to see what still needs to bolt on the engine before it goes back in the car. I was worried I might miss something and I was right. Found this heat shield

image by Team Illuminata Motorsport, on Flickr


and a temperature sensor that goes in the back of the refurbished head but this plug won't come out and I'm afraid of rounding out the Allen socket. Worst case I have to drill it out and retap it but then the head would have to come off!

image by Team Illuminata Motorsport, on Flickr


Tried this to no avail

image by Team Illuminata Motorsport, on Flickr


So resorted the the impact gun which thankfully worked. I forget how effective they can be.

image by Team Illuminata Motorsport, on Flickr


Then I celebrated by reinstalling the subframe.

image by Team Illuminata Motorsport, on Flickr

team illuminata

Bought some inspiration over the weekend.

image by Team Illuminata Motorsport, on Flickr


It inspired me to go on a spending spree. Ordered air box grommets/mounts and filter.

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr


Oil can gasket

image by Team Illuminata Motorsport, on Flickr


Bomb mounts

image by Team Illuminata Motorsport, on Flickr


Trans oil

image by Team Illuminata Motorsport, on Flickr


and about $300 worth of vacuum hose, clips and copper washers!

As I can now see light at the end of the tunnel I also turned the engine round on the hoist so it's ready to go in. A little optimistic perhaps?

image by Team Illuminata Motorsport, on Flickr