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Audi UR Quattro Rally Build


Old 04-01-2018, 03:32 PM
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This concept of refurbishing parts then bolting them to the unpainted shell is working out well as we have already discovered a few things we need to mod and are accumulating quite a parts list too.

We got our first batch of parts back from powder coating:

And wasted no time attaching some of them to the car. Front sub=frame for instance:

We also received a Sparco battery cut-off for the dash:

Our friend Paull is concurrently building an RS200 replica with a Focus RS crate engine. He brought over his superfluous factory intercooler to see if it might work for our application. Maybe:

We finished the refurb on the steering column but it is going to need a bushing sleeve replaced before being put into actual service. However, this didn’t stop us bolting it up along with the refurbished pedal assembly:

We thought our pedal assembly was in pretty good shape, until we took the over-center spring apart to clean it:

Add that to the parts list. Stll, it didn’t stop us bolting it to the car:

We also spent a bit of time prepping some parts for plating. We are having this lot zinc dichromated so they need sand blasting first. It was suggested filling the cylinder bores with hot glue so they wouldn’t get sand blasted so we gave it a try.

We took the opportunity to test fit the dash as we suspected it would interfere with the steering column. We were not wrong. There’s a reason for that cutout after all:

We plan to continue to assemble the car this coming week so look for an update soon.

Last edited by team illuminata; 04-01-2018 at 03:39 PM.
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Old 04-05-2018, 04:40 PM
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What do we mean by “fronts”. Well, we have opened up quite a few areas of work on the car, none of which seem to be nearing completion: namely:
• transmission,
• plating
• pedals
• dash
• shifter

We have power washed the transmission and replaced axle seals but we broke a tab off the rear output unit and only just found a spare transmission to steal one off. Now we will disassemble that and replace both seals. Fortunately the bearing in this one is in great shape so it actually saved us some money and time.


Still have to clean the trans and replace the input seal. Then install the shift linkage we recently refurbished.

Along with the calipers we prepped for plating we also have dozens of fasteners and brackets to re-plate. To help with the cleaning process we bought a vibrating parts cleaner from Harbor Freight. We are still learning what media works best for what degree of rust etc.

We did make some progress with the shifter in that we managed to disassemble it. Without breaking anything either!

The reverse lock-out tab is bent but otherwise it’s OK. We ordered a short shift kit from 034 Motorsports for it too 

We laid down some plywood floorboards after installing the pedals. The floor was very uncomfortable to kneel on and our work boots made it dirty. This will be a lot more convivial.

We still need to find the accelerator pedal, get the dash to fit over the steering column and also fill it with gauges and switches.

Lots to do!

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Old 04-13-2018, 02:12 PM
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We made quite a lot of progress this week but it doesn’t feel like it. Perhaps because we didn’t get to actually bolt anything to the car. What we did do was finish prepping the transmission. We replaced the rear coupling and seals with a non-broken version, cleaned and painted the case, installed new drain and fill plugs, replaced the input shaft seal and installed the mounts and brackets. Mounts are 034 Motorsport in Delrin.

People keep telling us we really need to run with the big, heavy rubber damper mounted to the back of the transmission as Audi intended but we’d really rather leave it off. Are we nuts?

We also managed to recommission our ancient, homebuilt sand blaster and put it to work on some rusty components. Unfortunately, in our excited state, we forgot to take the “before” pictures.

Next week we hope to modify the dash to fit over the steering column and get some parts plated. We will also look for something to bolt to the car. Exciting!!!!!!!

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