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The 1983 Ur.

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 Post subject: The 1983 Ur.
PostPosted: Tue Dec 13, 2011 2:56 pm 
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Suppose i should post up some pics of my own "little" project then!

Way back in 2009 ( damn that seems like such a long time ago!) i was looking around for an Ur as a project.
Before that, the last Audi i had was in 99, a coupe gt that i had for 13 years when it got rear ended and written off, after that i had a toyota celica which was a good car but i took out the 2.0 litre turbo motor and transplanted in a 3.0 litre v6...oh and kept it 4wd.

But my heart was never really in the toyota and i always wanted an Ur, so i went looking.
Lots of possibles came up and its a bit of a lottery to try and get one thats not so far gone that itd take years to get fixed up........still mines not done. :)

Anyhow, it was found down in Suffolk, a US serviceman based at RAF Lakenheath was running it round but i think it bankrupted him so he was selling it.
A deal was struck and i got it trailered home ready to start killing my wallet. :P

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Although it looks pretty good on the photos i found plenty to fix, starting with the motor.
I already knew the original 10Vt was coming out so me being me, i bought the 20vt AAn motor to replace it with around 6 months before i bought the car...
The main idea being to replace all the tired and worn out parts and refurb it to new spec with a bit of extra grunt and hopefully reliability.

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Didnt take long to strip the heck out of it, within a day or so of getting it back id already gutted the insides to look for rust (found some) and the engine came out in the next few days.

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Lots wrong in the engine bay... right side mount..

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Although it was a runner, it didnt run particularly well so i decided to strip the motor.
Just as well really because it was almost entirely shot to bits and was in danger of grenading.

This is whats left of one of the exhaust guides.
Javads piece on the exhaust valves losing heads comes to mind here.
Max valve rock at the head is supposed to be 1.3mm....i had over 5mm... :o

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Theres simply no supporting material left, its entirely worn away.
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Also found cracks in the head that went way too deep and one of the exhaust valves had a partial failure in the form of a crack.

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You can just see the crack across the seat and partway round the valve head.
Thatd have made a bit of a mess i reckon.

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The right side wing was removed as i noticed it had been removed before, turns out a light front end shunt was the reason.
Also it hadntbeen resealed properly so the road salt and water had gotten underneath and rotted out the mounting flange partially.

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 Post subject: Re: The 1983 Ur.
PostPosted: Tue Dec 13, 2011 3:21 pm 
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I sprinkle rubber on my Cherios
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Nice!


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 Post subject: Re: The 1983 Ur.
PostPosted: Tue Dec 13, 2011 3:25 pm 
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Took me a while to clear all the nasties out and get it ready for a repair but that didnt take too long and came out fine.
At this point ive only removed the loose stuff.

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I then proceeded to strip the engine bay out completely of all the pipes and steering rack etc, before stripping it back to bare metal.

Renewing any seam sealer that was peeling i primed it with acid etch primer and a couple of coats of high build.

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Once dry, i could paint it the proper colour- Montego black metallic.
No clear coat here yet but it looks quite attractive in that satin finish.

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Once clearcoated i could leave it to harden.

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And refit the steering rack before doing a test fit of the 20 valver! :D

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My poor car. No front sus, no electrics, no lights.

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Speaking of lights, i never liked the single piece cibies so i sourced a set of quad h4/h1's.
A good friend in massachusetts managed to find me a set of the plastic surrounds/trims in good condition and sent them over, i still feel much indebted to Matt for that kindness. Cheers buddy!

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More mess to clear up under the scuttle.
It had been crudely chopped into to get access to the clutch master instead of just dropping the pedal assy out, not good, let water in which destroyed the steering column bearing and wet the carpets and electrics.

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I removed all that a couple of months ago and made it right.

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Another friend was stripping a coupe gt and he donated the scuttle panel which i cut to fit over the existing area after clearing out all the old corroded and damaged material.

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The hole is for the aan wiring harness to pass through, the ecu being mounted under the dash .

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Sound deadening applied.

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A quick look at the front pretty much as it stands today.
Brakes are now vacuum servo with an audi 80 master, RR 20 valve brakes on the rear, all new shocks, bearings seals, discs ball joints....

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The saga continues...


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 Post subject: Re: The 1983 Ur.
PostPosted: Tue Dec 13, 2011 3:40 pm 
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mach 2 with my hair on fire
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Location: Holladay, UT
Very nice project. I have something similar in the works right now. I just need to catch my thread up a little bit as it is currently stripped down to the shell...

Looking forward to more updates.

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 Post subject: Re: The 1983 Ur.
PostPosted: Tue Dec 13, 2011 3:50 pm 
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I like it. Welcome to the forum and thanks for bringing your project here. It makes me want to go work on my Urq project.

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01 225hp Audi TT
83 Mars Red Urq 2.5l 20v stroker (dream stage)
06 2.0TQ S-line A4 (wifes)...Swagger Wagon is history
00 VW 1.8T NB (daughters)
97 HD F250 Powerstroke
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 Post subject: Re: The 1983 Ur.
PostPosted: Tue Dec 13, 2011 5:03 pm 
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Location: Montauk, NY
very nice, body looks extremely straight.


Another 20vt URQ project to add to the mix haha

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1983 Audi Quattro 20vt
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 Post subject: Re: The 1983 Ur.
PostPosted: Tue Dec 13, 2011 5:10 pm 
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mach 2 with my hair on fire
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Location: Milton, Canada
Very nice, looking forward to more updates!
Cheers

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www.quattro.ca
82 Ur-q - SQ project, long term
82 4000 2-door
83 80 q - Euro 2-door!!
85 Ur-q - Euro with 3B
86 4000 quattro with 59,000km on the clock
86 5000CD quattro avant, all original
91 CQ winter sled
93 90q - 2.5TDI, 6-speed
93 80q Avant - 2.5TDI, 6-speed in the works
94 S2 Avant, stock


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 Post subject: Re: The 1983 Ur.
PostPosted: Thu Dec 15, 2011 12:04 pm 
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Location: Vancouver Island -its nice here
Hey Tony;
Glad you finally made it over here. Thanks for your previous help on the glasswork.
Cheers
Keith


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 Post subject: Re: The 1983 Ur.
PostPosted: Thu Dec 15, 2011 12:19 pm 
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mach 2 with my hair on fire
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Location: Near Sacramento. Sometimes at Derracuda's place(Oregon)
Nice job so far. I've always been a fan of the montego black and I love that rear spoiler, every urq should have one.

Was the car repainted? I noticed the ring stickers on the doors are partially on the fender and the rocker. Or did they come like that over there.

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1985 4000S quattro AUX 40V 4.2 - Just about to get S8 40V and new face.
1984 UR quattro Lotsa Mods.
1991 200 20VT
1990 Jetta GLI 16v
1989 Jetta Coupe
4 Toyota 4x4's
1969 Plymouth Roadrunner- SOLD 5-7-11
1970 Boss 302 Mustang
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 Post subject: Re: The 1983 Ur.
PostPosted: Thu Dec 15, 2011 2:26 pm 
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Following... nicely done.

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 Post subject: Re: The 1983 Ur.
PostPosted: Fri Dec 16, 2011 9:00 am 
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Hiya keith, glad i could help buddy! :)

@40v4kq, Yes it was originally owned by an oil company owner and for some reason he had it painted in plain old black which looks good enough but hardly the right colour.

Ive no idea who decided the rings should be down on the sills tho so as with the paint, theyre coming off, the paint will be reinstated as per what it hould be and the rings will go back on the doors, plenty left to do in this one yet tho!

Finally got the diff seals refitted, diff bolted in, left rear driveshaft in, propshaft as well after putting a new centre bearing on it.
Just trying to find a method to tighten the prop to diff/to gearbox bolts now as most of the tools ive got wont go in! aggh!


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 Post subject: Re: The 1983 Ur.
PostPosted: Fri Dec 16, 2011 9:04 am 
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4v6 wrote:
Just trying to find a method to tighten the prop to diff/to gearbox bolts now as most of the tools ive got wont go in! aggh!


Should be a 6mm allen hex key. How did you take it apart?

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Martin Pajak
www.quattro.ca
82 Ur-q - SQ project, long term
82 4000 2-door
83 80 q - Euro 2-door!!
85 Ur-q - Euro with 3B
86 4000 quattro with 59,000km on the clock
86 5000CD quattro avant, all original
91 CQ winter sled
93 90q - 2.5TDI, 6-speed
93 80q Avant - 2.5TDI, 6-speed in the works
94 S2 Avant, stock


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 Post subject: Re: The 1983 Ur.
PostPosted: Fri Dec 16, 2011 9:51 am 
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Very nice, great inspiration to go work on mine

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1982 Porsche 911 SC
1983 Audi UR Quattro project
1987 Audi 4000 Quattro
1990 Audi Coupe Quattro


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 Post subject: Re: The 1983 Ur.
PostPosted: Fri Dec 16, 2011 10:34 am 
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Hey Martin, yeah i used similar to get it all apart, just want to torque the new bolts up as per spec but cant get the torque wrench in. :) Yet!


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 Post subject: The 1983 Ur.
PostPosted: Fri Dec 16, 2011 11:14 am 
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Location: physically: NH, Mentally: A different planet!
I typically use 6" long 1/4" drive BALL END Allen keys.

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 Post subject: Re: The 1983 Ur.
PostPosted: Fri Dec 16, 2011 2:46 pm 
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Nice job - keep it up. Thanks for sharing it with us.

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 Post subject: Re: The 1983 Ur.
PostPosted: Fri Dec 16, 2011 4:39 pm 
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Luckily i finished all the outstanding welding work to the monocoque itself a couple of moths back, but its been quite a long process because as we all know repair panels are pretty hard to come by and the price can be high.
Thats been a major reason for the time to do this so far, its been done on a very restricted budget.
If id have had to subcontract out the work to the body, ie the welding and panel fabricating jobs, i couldnt have done it, itd have been too expensive, so panels/patches had to be made not bought.
Its been expensive as it is what with almost all parts being replaced for new, but that cant be helped and i always counted on doing it pretty much like i have, besides, i never really "own" a car until ive had its guts out all over the floor and know everything i can about it. :-)

So anyway, a few more photos.
The climate in this country isnt too grand at the best of times, heck it peeved the romans no end and even they buggered back off to sunier climes, so its hardly surprising that the poor old quattro was suffering from some weather and monkey induced damage.

One of the first jobs was to start repairing the jack up damage to the sills.
Obviously some folks dont give a hoot about where a jack goes and it shows...

The damage here has come about because the body coatings been damaged by jacking up without due regard to protection of it with a rubber pad or similar, rust gets a hold and the whole area gets weakened.

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The end of the sill had broken away (behind where the trailing edge of the wing bolts down) and a quick shot with the grinder had it away meaning i could take a picture inside the sill.
Still had the original wax in place but obvious signs of rust creeping along the seam which needed cutting out.

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This is on the drivers (rh side-im uk remember) and the corrosion extended about 18 inches along.
3 layers of steel to get to grips with here and rebuild it all to be as close as it could be to stock.

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At this point ive removed all the rot from that damaged area and made good the end of the sill.
Still needed final fettling but thats just cosmetic.
The whole area is very much more solid than before, i felt at one point id be like Fred Flintstone with my feet providing stop and go action...

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A spot of bubbling at the rear arch turned into a major job.

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Cutting the affected part out revealed a corroded inner arch as well as its return flange...agh, hate doing these, theyre so involved!

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Always turns into something bigger dosent it?

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Not too put off i formed a cunning plan....... to forget all about refurbing it.....well not really i was quite into it at that point. :-)

Leading edge of the arch was toast as well as the jacking pont at the rear.
Lots and lots to think about here, not least keeping the relative shape of the arch and its structure in 3d space.....headaches.

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First thing- leave the inner arch alone at this stage and fabricate up the outer skin replacement, you can still hang that where it should be using what you still have of the old material under it.
Fabricating that skin wasnt easy either as it has more than a few elements to it and shape and contour changes, and im no panel beater.
I am dogged tho which might be helpful. :P

Started like this.
Made a cardboard copy (very rough indeed) of the basic shape by impressing the edge shape onto it from the car then transferred it to sheet steel and starterd to hamerform the curve of the flange.
First ever attempt at something so complex.

Sturdy metal table is oh so useful. And ear defenders.
Pryed up an edge bit by bit all around the curve then steadily hammered it into shape.

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Until after a few hours of clanging and no doubt irritating the neighbours across the way, i got this panel made up.
Quite pleased with it, but did it fit?

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Heck yeah! Pretty much on the money. Only needed to be fettled to fit the hole id cut out and then itd be good to go.

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Self congratulations and much handshaking gave way to the sudden realisation that the inner flange and arch was going to be a sight harder as it had an even more extreme shape....how the heck?

Can only say that i went at it in the same manner, cardboard, steel, table, little block of wood and a hammer or two.
Surprisingly it seemes to have been easier than the outer skin, at least thats what i felt about it. :?
It too came out pretty much on the money, such good luck!

One on top of the other.

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Presenting the inner repair arch panel up and marking a place to cut it to and lap weld it in place took a while as it was a judgement call on where to remove the material to as i had to get the rot out and try and juggel all the points it needed to pick up, still it worked ok.
Obviously just tacked on here.

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By now it was time to address the jack up point and sill corrosion.
1mm cutting disc did the job nicely.

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And allowed me to fabricate a repair.

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Along with an end to the box section to tie it all in when ready.

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Once happy that it would all go in as it should i set about prepping up to weld it all together.
I used plug welds and did them infrequently to prevent distortion as much as possible.

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I didnt seem to encounter any real issues as it all just "went in" ok. Weird really as its quite a complex repair now that i look back at it.
Wouldnt want to take it on for someone else i must say.

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Barest skim of filler later and its looking pretty good.

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Just in time for the other side.....


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 Post subject: Re: The 1983 Ur.
PostPosted: Fri Dec 16, 2011 5:03 pm 
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mach 2 with my hair on fire
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4v6 wrote:
Surprisingly it seemes to have been easier than the outer skin, at least thats what i felt about it. :?
It too came out pretty much on the money, such good luck!



Practice makes perfect...I'm sure that helped with the second internal repair...and I'd hardly call it luck...Looks like the fruits of a tactful approach and a patient set of hands.

Great work!

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 Post subject: Re: The 1983 Ur.
PostPosted: Thu Jan 05, 2012 3:08 pm 
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Well with all the welding finished ( theres way more than ive shown) and the metalwork sorted out, i could start on the rear suspension and drivetrain components.
When i got the car, even though i never actually drove it any distance, just moving it around on the front i could tell there were issues with it, like some groaning, doinging and ominous creaking sounds.
Turns out at some point its had the original rear springs taken off and some aftermarket "stuff" fitted on that dosent well, fit.
Heres the source of all the creaking and groaning.
Spring coils are over the cap which were fractured..
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Other side was no better.

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Bump stops were shot to bits as were all the top mounts, wheel bearings, brakes, all the subframe rubbers, balljoints, wishbone rubbers and toe control arms.
Complete overhaul was the order of the day.

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Diff seals were leaking so they were on the agenda also.

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Original 1983 rear damper inserts were well past it.

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Underside was pretty clean, just oily from the diff.
Removed all the heat shielding to check behind and fabbed up a new section at the rear.

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Prop centre bearing was shot to bits as well, new one has replaced this tired old fella.

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Also finished off part of the wiring harness for the AAN motor.
I decided not to cut the body around, instead running the harness from the drivers side (RH) out under the scuttle thru the hole i made in the repair panel and thru the various holes that aready exist.
Once the rainwater deflectors on none of that will even be visible.

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In between doing that and various other stuff, i repainted the rear subframe and refitted all the new components i had assimilated over the course of a year or so all in readiness to get it done.

Looks like theres a dead body dropped out from under the subframe...was mine i think.

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Then proceeded to do a check on every bolt for correct torque, marking it with red as i went.

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Dropped the rear box on its mounts to test fit it and see how much room i had.

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Plenty as it happens.

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Since im fabricating the front to rear run of the exhaust myself, whats the consensus of opinion regarding that first box before the subframe? Include one or omit it?
Dont get me wrong, i love a 5 cylinder but my old coupe gt made my ears bleed at some points in the rev range and set off car alarms, used to boom some, so im trying to avoid that if at all possible.
Probably have to try it and see huh?


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 Post subject: Re: The 1983 Ur.
PostPosted: Thu Jan 05, 2012 4:26 pm 
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Location: Las Vegas, NV
I left my middle resonator out of the exhaust. I worried some that it might drone or be too loud, but as it turned out it's not bad. There really isn't any highway drone to speak of, but it's a bit loud coming off the line hard. There are already those that say it needs to be louder, but I'm quite sure my wife will think that it is too loud, so I it's staying as is and I'm hoping I can talk her into a few long distance runs with it. I think that I about have her talked into running up to the Pikes Peak event this year. I say leave the middle resonator out. Oh and I also have a CAT delete going on right now so I'm open from the turbo to the rear muffler.

I don't know if you have watched my latest video, but it will give you an idea of how loud mine is.
http://motorgeek.com/viewtopic.php?f=6& ... &start=800

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John Iroz

01 225hp Audi TT
83 Mars Red Urq 2.5l 20v stroker (dream stage)
06 2.0TQ S-line A4 (wifes)...Swagger Wagon is history
00 VW 1.8T NB (daughters)
97 HD F250 Powerstroke
07 ST1300


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 Post subject: Re: The 1983 Ur.
PostPosted: Fri Jan 06, 2012 3:51 am 
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Joined: Sat Dec 10, 2011 7:44 am
Posts: 46
Hi John, thanks for that.

Yeah i spent the best part of two hours or so looking through your project progress including the video up the mountain!
Excellent stuff and inspiring too. Love that soundtrack.
Glad to see im not the only one who has a problem with a kid trying to take the Urq over, got one here doing the same. :)


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