Rob's Ur Quattro

[RobClubley]

Should have bought a bigger puller.

Made a start on the first of the CV joints - got one degreased and partly re-assembled. I would have done both ends if I'd bought a big enough puller!

This is one way to separate the bigs

I also took the cup thingies off the gearbox, cleaned them up and re-fitted, and moved the jack stands at the back so I can get the rear subframe out for cleanup and new bushes.

Then it's brake lines, sort out the exhaust heat insulation which is hanging off - and have a look under it to check for rustyness.
And I should be able to get the rear fully re-assembled. 

Edited 26 March, 2017 by RobClubley

[RobClubley]

Where we're going...we don't need roads.

Finally got the rear subframe off. It's in decent condition under the muck. Bushes are shot of course.

Now struggling to get the shaft back together

I thought the subframe was the last part that needed to come off. But I noticed that the fuel line has been rubbing on the rear diff mount and is this close to going through. Better sort that out then!! Imagine filling it up and losing 80l of fuel, not to mention the fire/explosion risk.

[skomaz]

Those part are looking much better and seems to be progress (if slow and hard going!)

[RobClubley]

Yep I'm getting there!
If I had more time...

[vrskeith]

One for you to indulge in Rob, take a break :http://www.evo.co.uk/news/19140/audi-to-display-motorsport-cars-from-its-illustrious-past-at-events-throughout-2017

 

Enjoy!

[RobClubley]

Got a few more bits cleaned up and painted.

These are ready to go in

[RobClubley]

Being able to bolt some clean parts back together is very satisfying.

[RobClubley]

This is the fuel line from tank to fuel pump. It has been rubbing the rear sub frame mount The dash gauge told me the tank was just about empty, so I got my five litre container and started to drain the tank. 24 litres and a bit of a spill later...
The whole house still smells of petrol.

I struggled for ages to get these out then remembered I had the capability to make fire. It still took me another hour to shift them. So much rust!

Edited 10 April, 2017 by RobClubley

[boylers11]

Love the bush removal technique, can't beat a bit of caveman mechanicing!

[boylers11]

Love the bush removal technique, can't beat a bit of caveman mechanicing!

[RobClubley]

There was a blowtorch involved too

[RobClubley]

Another brake line almost done. Needs a little tweaking but I'm pretty happy with it.

 

[RobClubley]

Had a day off work today so I got a few hours with the quattro.
Making brake lines takes ages! Got them all in place now, hopefully I make them properly.

Sam was unimpressed.

I also cleaned up the rear subframe and slapped some paint on it.

And the rear wishbones.

Then suddenly it was 3pm and time to pick up the child from school!

I have a new rear mount for the rear diff, but it needs to be pressed in, and three of the bolts holding the bracket on are rounded off and rusted in. Sigh. So the rear diff needs to come off to get it done. Gives me the chance to clean it up I guess. 

[mannyo]

Coming along Rob,

 

Looks like its been 2 years nearly in the making now. I bet you can't wait to drive it around NZ.

[Titanium_Man]

2 hours ago, mannyo said:

Coming along Rob,

 

Looks like its been 2 years nearly in the making now. I bet you can't wait to drive it around NZ.

Jeez, this build been going that long!!  (No dig, just a realisation how time flies!!) 

[RobClubley]

Yep coming up to two years. Given that my original goal was one year and about $15k, both have been passed by significant margins now.

Ah well, it's my dream car and it will be awesome when it's done with all new paint, suspension and bushings.

 

My current aim is the national meet of the local VW/Audi/Skoda club in September. It's a five hour drive away to a race track, though I won't be taking the quattro on track this time.

 

Just two more major purchases to make now I think - a shiny Milltek exhaust and the shopping cart I have waiting at Audi Tradition in Germany.

[RobClubley]

[RobClubley]

Still working on getting these buggers out. They are allen bolts, honest!

[VRS Mike]

Some good progress Rob. Have you addressed the additional holes in the chassis or can that wait till she's back on the road?

[RobClubley]

3 hours ago, VRS Mike said:

Some good progress Rob. Have you addressed the additional holes in the chassis or can that wait till she's back on the road?

 

Not yet, when it's driving again I'll take it to a specialist. 

[kentphil1]

This is truly epic Rob, Hope you are making good notes where everything goes.

[RobClubley]

 

Hammering an old imperial socket on them did the trick, combined with my 12v impact gun.

[RobClubley]

Rear drive shafts cleaned up. They're not in bad condition, under the muck. Need to collect some bits from The Toy Shop Wellington who have been pressing things in and out for me, then I can bolt some stuff back on.

[RobClubley]

Picked up my stuff from The Toy Shop Wellington. Various bushings pressed in and out. I had to strip and re-assemble one of the cv joints. It wouldn't move properly because I'd assembled it incorrectly.

Rear diff mount and front drive shafts are in place.

Front sub frame is assembled and ready to go on.
It feels great to finally be bolting some clean parts together.

[RobClubley]

I couldn't resist those extra 25kW