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Audi UR Quattro Rally Build

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Tue May 21, 2019 4:09 am 
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Looks great! Can't wait to stop by and derail progress.

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu Jun 13, 2019 8:27 am 
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ENGINE REFURB 2

We know, engine stuff. (Focus TIM). But look what arrived this week!

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We could have just tried to convince you that we had a surge of enthusiasm and finished the car but that wouldn't be right.

We did paint something though, as promised:

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Gold too!

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and red!

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We also had a go at cleaning up the oil pan. It's not obvious in the pictures but it did make quite a bit of difference.

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Enough that we think we might want to have another go at the transmission case with this stuff.

The last thing we worked on this week is only peripherally related to the engine but, as we were about to send a load of parts to the platers we wanted to include the power steering lines fittings. This is the 83 URQ's lines and oil tank along with the AAN's pump. The gap on the lower run is where the accumulator would go for the power brakes but as we are not using power brakes we can dispense with that. That means we need to come up with one continuous high pressure line and also some fittings for the pump end.

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We sourced a high pressure line from a servo boosted car as it's fitting routes better around the steering rack because it does not have to go first to the accumulator. Then we cut out all the fittings and sand blasted them ready for plating.

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu Jun 13, 2019 5:48 pm 
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Are you going to be running the URQ rack with the AAN pump?


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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu Jun 13, 2019 11:31 pm 
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quattrofan wrote:
Are you going to be running the URQ rack with the AAN pump?


That's the plan at this point. Why?

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Fri Jun 14, 2019 7:27 am 
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The urq up to the RR used a 75bar pump and rack. I believe the all the later cars are at least 100 bar
I know some people are using a later pump but the possibility exists that u can blow the seals out. My rack rebuilder confirmed this.

I would like to use a later style pump with the 7A bracket so I can keep an original look but I already rebuilt my original rack.

Options are available. Easiest if your car is still apart is to use a newer 100bar rack. If you want a rebuilt rack maybe I'll sell mine :)


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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Fri Jun 14, 2019 8:39 am 
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quattrofan wrote:
The urq up to the RR used a 75bar pump and rack. I believe the all the later cars are at least 100 bar
I know some people are using a later pump but the possibility exists that u can blow the seals out. My rack rebuilder confirmed this.

I would like to use a later style pump with the 7A bracket so I can keep an original look but I already rebuilt my original rack.

Options are available. Easiest if your car is still apart is to use a newer 100bar rack. If you want a rebuilt rack maybe I'll sell mine :)


Interesting. We did know the later pressures were higher. We assumed the URQ rack could handle it. Not sure now. Maybe we would be interested in your rebuilt rack. Even MORE interested if it is quicker!

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu Jun 20, 2019 7:43 am 
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Quattro Rally Project - Hot Side Engine Refurb

This week we turned our attention to the hot side of the engine and removed the turbo, exhaust manifold and waste gate. The turbo will be sent out to be refurbished, the exhaust manifold will be replaced with a slightly better one and the waste gate will be, well, we are not sure. We know we are not keen on the red cover however.

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This is the eBay special $85 exhaust manifold we got. If nothing else it doesn't need sand blasting! When the turbo comes back we will have to decide whether and how to refinish it.

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Inspired by our gold coil cover we finished the rest of the valve cover. We know, it's a bit flash but it is rather reminiscent of the Group B 10 valve engines so we feel good about it.

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Then we got distracted again and made a fake license plate. It's the little things...

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu Jun 27, 2019 5:12 am 
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Turbo Trouble & Fuse Dash Panel

We received some bad news from our turbo shop, G-Pop Shop this week. Our turbo is bad. Exhaust turbine ate something that didn’t agree with it.

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We got on the blower to our engine supplier, EFI Express and they soon had another core sent out. This one turned out to be fine. The other good news is that the bad turbo was never on our engine, it was just one of many EFI Express had on the shelf so whatever did the damage almost certainly did not pass through our engine. PHEW. Can’t wait to get the refurbished turbo back now.

While that was all playing out we reassembled our belt tensioner. These are NLA and ours had a bad bearing. We sourced and new bearing but had to make our own rivets to put the pulley back together around it, followed by a lick of paint of course.

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We also continued to work on our dash mounted fuse panel design. The original works cars had three fuse blocks holding ceramic fuses mounted through the center removable panel. We want to use three similarly sized panels but with more modern blade fuses. You’d think that would be quite simple but it’s proving quite difficult. We can find side entry versions but our wires have to come in from the rear.

Group B fuse blocks:

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The collection of candidates we have assembled so far:

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The one on the bottom right would be perfect if it held 12 fuses instead of 8. You’d think that were available wouldn’t you. Nope. We may have to compromise.

Now we have the wheels on the car the only thing stopping us putting it on the ground was the lack of springs. That and a good reason to actually do so. Undaunted we installed the springs.

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu Jun 27, 2019 5:31 am 
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I used a 75 bar pump for my setup with custom lines from a hydraulic shop , this way I could have a swivel fitting on on end .
Aside from pump pressures another thing to take note of- in the high pressure line to the rack, the line does have a hidden restrictor of some sort in it - I’ve heard it’s for pressure waves and/or noise .

On your oil pan it looks like you have the stock urs4 oil pan on that engine? If you are planning on running stock location radiator, have you test fit it with the radiator in the car? The 7A pan has an indent on drivers side and extension on the other to allow the bottom corner of the stock rad to fit. With the large chassis pan you MAY have a clearance issue .

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu Jun 27, 2019 7:47 am 
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Afterthought wrote:
I used a 75 bar pump for my setup with custom lines from a hydraulic shop , this way I could have a swivel fitting on on end .
Aside from pump pressures another thing to take note of- in the high pressure line to the rack, the line does have a hidden restrictor of some sort in it - I’ve heard it’s for pressure waves and/or noise .

On your oil pan it looks like you have the stock urs4 oil pan on that engine? If you are planning on running stock location radiator, have you test fit it with the radiator in the car? The 7A pan has an indent on drivers side and extension on the other to allow the bottom corner of the stock rad to fit. With the large chassis pan you MAY have a clearance issue .



Thanks for the good information Afterthought.

We have not yet test fit a radiator. Currently we only have a stock one to hand but want to do a bigger aluminum one. However none of the regular suppliers have returned my emails so we might have to build one. If we do that I assume we can make it miss the oil pan.

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu Jun 27, 2019 4:30 pm 
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This is the bottom of mine clearance wise . So you can always swap the pan and or make the radiator fit .
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I have the $1200 Ron Davis radiator. If I remember correctly that’s what 034 and 2bennett used as well, I later found out those are known for leaking and some have lasted even less than a year . So with my next build I will do a bell core for around $500 and make the end tanks with a brake .

There are these as well

https://rover.ebay.com/rover/0/0/0?mpre ... 4065799615


On the power steering hose this is the location of the restrictor. If you don’t run it you might get a really funny noise at certain times from the pump - that is what happened to me in hot weather .
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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Fri Jun 28, 2019 12:58 am 
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Thanks.

Our pan looks a little different. Perhaps it will clear.

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Ron Davis was one I emailed. Sounds like their radiators are as bad as their customer service. Sounds like we are building our own. The engine is close to going in so we will see how much room we have.

We saw that restrictor on the line we disassembled. Think we still have it somewhere. If not we'll buy some earplugs.

Thanks for your input.

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu Jul 04, 2019 11:17 am 
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Quattro Rally Build - More Engine Bay Work

More distraction this week but look at it! Wouldn't you be distracted?

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Some of this is for the engine refurb but some has been holding up some ancillary stuff so we got busy. We installed the wipers (can you spot the long awaited plated parts?)

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This piece of automotive jewelry holds the blower motor resistor!

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Alternator fan (that's engine related)

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Power steering rack fittings.

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and the front left tie rod adjusters.

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We even got our anti-roll bar clamps back.

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So we got to cross a ton of stuff off the list; all be it, little stuff. Still, it's all progress, right? Got to keep moving forward.

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu Jul 11, 2019 8:44 am 
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It's Time to Get Serious - Cold Side Engine Reassembly

This week we started on the serious reassembly of the engine. We’ll try not to get distracted. We started on the intake side as that has the most shiny bits ready to go. First up the modified alternator mount:

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Then the coolant adapter. We were advised to get a straight one in metal for better fitment:

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Then we installed the alternator, power steering pump and belt tensioner:

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We still need to find a shorter accessory belt but that’s not what’s stopping us completing the intake side of the engine; we need an intake manifold solution. Because the radiator on the UR Quattro sits the side of the engine, the AAN throttle body would interfere with it because that is located on the center of the AAN intake plenum:

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We either need to modify our stock one or source an aftermarket version with the throttle body on the front. We favor the aftermarket options from BST, Wagner or whoever else sells one. Unfortunately finding one is proving troublesome as they are basically NLA. Let’s see what we come up with.

Hey, look, we didn’t get distracted. Next week’s topic will depend on what shows up first: a refurbished turbo or a cool intake manifold.

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu Jul 11, 2019 8:19 pm 
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To run that setup with serpentine belt but less the AC compressor , look at NAPA belt part number 25060509 . I think it’s from a ford excursion or something . It worked for me

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Tue Jul 16, 2019 7:14 am 
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Afterthought wrote:
To run that setup with serpentine belt but less the AC compressor , look at NAPA belt part number 25060509 . I think it’s from a ford excursion or something . It worked for me



Thanks for the input. We actually just guessed and lucked out first time. :)

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu Jul 18, 2019 7:42 am 
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Refurbished Turbo - Hot Side Engine Reassembly

The turbo won. Turns out it takes longer to find a unicorn aftermarket intake manifold than it does to refurbish a turbo. Well it does if you are a professional outfit like G-Pop Shop https://gpopshop.com/

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So we’re going to assemble the exhaust side next. First we’ll need a heat shield:

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Our new exhaust manifold fit well but we did have to shorten some studs to get the nuts on.

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The rest was easy bolt on stuff. New gaskets of course.

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And we think we’ve found an intake manifold. Subscribe if you want to find out what kind.

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu Jul 18, 2019 9:40 am 
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did you see this reverse inlet option on S2forum? https://www.s2forum.com/forum/member-s- ... e-manifold

https://i.imgur.com/qb8vPNU.jpg

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu Jul 18, 2019 2:51 pm 
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audiPete wrote:
did you see this reverse inlet option on S2forum? https://www.s2forum.com/forum/member-s- ... e-manifold" onclick="window.open(this.href);return false;

https://i.imgur.com/qb8vPNU.jpg" onclick="window.open(this.href);return false;


Er, no. is it available?

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu Sep 12, 2019 10:12 am 
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Solving Intake Manifold Challenges

We found an intake manifold!

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It’s a new old stock from Wagner Tuning. A fellow Audi nut had it in his stash and no longer had plans for it. We do! This thing should be plug and play and make moving forward very easy. We test fitted it with the 034 Motorsport phenolic spacer kit and it fit perfectly! Trouble is, nothing else would fit to it. Firstly, the throttle body and power steering pump now want to occupy the same space:

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And the fuel rail won’t fit and has nothing to bolt to. At least the injectors line up with the injector holes and there are no inserts to source.

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Time to get creative……….

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu Sep 12, 2019 10:17 am 
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There is an aluminum spacer that goes with that which I have. I will add a picture later


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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu Sep 12, 2019 10:26 am 
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For the fuel rail there are two different styles of bolting , 3B and AAN are different . You’d need like the 3B style mounting instead of AAN . I used a fuel rail from EFI express

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu Sep 26, 2019 6:42 am 
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Solutions for our beautiful intake manifold

Last time we conversed we were reveling on the beauty of our aftermarket intake manifold and despairing at the frustration that nothing would fit around it. Now we think we have solved all these issues. Read on:

First we made a throttle body adapter to place the throttle body above the power steering pump:

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Then we started to hack up the OE fuel rail. We stripped off all the brackets and fuel lines to verify that we could use it. The injector holes lined up and the rail snuggled up nicely against the intake runners.

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Then we created fuel lines and incorporated an aftermarket fuel pressure regulator, a fuel pressure gauge and even a fuel sampling port!

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And somehow during this process the manifold itself got painted gold to match the valve cover.

We also came up with a way to secure the now floppy dip stick tube.

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We feel quite good about solving these problems. Of course there are a few minor details to work out such as the throttle cable angle of attack and mounting of ancillary items but they should be easy to figure out. At least now we feel it is time to introduce the engine to it’s new home so they can get acquainted. We do need to run brake lines and a few other bits and bobs around the engine bay before we bolt it in but it’s nice to have the engine out of the workshop.

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu Oct 10, 2019 8:38 am 
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We finally have a center console!

The saga of the OE center console is over! This piece took a very convoluted path to get to us from Germany but it arrived via (Friend returning from a trip to England) courier and couldn’t wait to install itself under the dash.

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This is the same piece used by most if not all the works cars and comes off lower spec cars not sold in the USA. We could have chopped off the lower half of the UR’s console but we really didn’t want to ruin one and it would never have looked so tidy.

The upper bay will house the OE heater controls, if we can find them again, while the lower bay is still up for grabs. We could install the OE cubby for storage, which would be useful as we’ve lost our glove box, but it might end up being home to the brake bias knob and USB ports. As a bonus, it does come with an accessory socket so there’s that!

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu Oct 24, 2019 7:30 am 
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Proper Gravel Rally Wheels!

We ordered more BRAID wheels for the car. This is the third set! We sold the first set including the tires. We have a problem. We justified this set of gravel wheels by ordering them double drilled so we can also use them on our 911 rally car. That car now has five sets of wheels yet only does about 300 miles a year. Did we mention we have a problem? Anyway, we think they look really cool.

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Even though they are ET20 they still sit pathetically inboard of the wide body fenders; as they should. LOL

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These are a classic BRAID gravel wheel in 15x7. Let’s hope these MRF rally tires don’t age out before we finish the car!

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