Man. awesome stuff.

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Old Aug 14, 2005 | 08:23 AM
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Default Man. awesome stuff.

<center><img src="http://pictureposter.audiworld.com/38899/rust001.jpg"></center><p>Sadly the driver's side is a little worse.
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Old Aug 14, 2005 | 08:31 AM
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Default less awesome now.

<center><img src="http://pictureposter.audiworld.com/38899/rust002.jpg"></center><p>One more day working on this side and it'll be ready. A good opportunity to weld in some thicker sheetmetal. Bumping to 14Ga is a BIG improvement in rigidity here.

The fender...
Its been suggested to get a coupe fender and slice off the flange that bolts to the unibody and weld that part to an urquattro fender. Or I could repair the urquattro fender with some sheetmetal, but I won't have those dimples. Any thoughts?
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Old Aug 14, 2005 | 08:50 AM
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Default

ArgggH. You yankees and your salt!
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Old Aug 14, 2005 | 10:40 AM
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Default fiberglass parts from NY.........

http://home.earthlink.net/~xtremecars/id18.html
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Old Aug 14, 2005 | 11:44 AM
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Default

Yeah I'm thinking that might be best too.
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Old Aug 14, 2005 | 10:06 PM
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Default Re: fiberglass parts from NY.........

how bad are your metal fenders? have a pic?
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Old Aug 15, 2005 | 05:30 AM
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Default They're not bad at all. I have a50 cent sized hole in the flange

right at the Shock tower. The rusting has delaminated the steel so I need to cut out about 8 inches of the flange and weld in a nice rectangle of new sheetmetal and it'd be fine, but it won't have those dimpled stamped features of the originals.
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Old Aug 15, 2005 | 07:42 AM
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Default Maybe Inner fender liners too?

As far as I understand, the 4000 (probably 2wd coupe too?) plastic inner fenders can be made to work as a retrofit upgrade.

If Audi had used them in the first place, all of us with the same urq rust problem wouldn't!
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Old Aug 15, 2005 | 08:19 AM
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Default for even more strength

you should make a bar or plate that runs from the door jam upto the piece you show in this picture.
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Old Aug 15, 2005 | 08:25 AM
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Default yeah

that little triangle piece is welded in there for frame stiffening, but I am thinking about overwelding it at the door jamb unibody. The factory welders just seemed to spot weld it and its barely in there. I know my rally car has a bolted in brace from the strut tower back through the firewall to the cage near the dash. I don't think they did any frame stiffening from teh shock tower down to the unibody near the bottom of the door. Perhaps they thickened the gauge of the sheet metal though. It would seem like a proper way to add more strength with minimal weight.
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