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team illuminata
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Post subject: Re: Audi UR Quattro Rally Build Posted: Thu Sep 03, 2020 10:44 am |
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I sprinkle rubber on my Cherios |
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Joined: Wed Jun 01, 2011 4:55 am Posts: 416
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team illuminata
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Post subject: Re: Audi UR Quattro Rally Build Posted: Thu Oct 01, 2020 10:09 am |
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I sprinkle rubber on my Cherios |
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Joined: Wed Jun 01, 2011 4:55 am Posts: 416
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Storage Unit Rally Car Build: Week 6 - Odds & Ends We installed some jewelry this week. Always nice when you bolt on some freshly zinc plated bling:   We also dug the PVC system out of the boxes.  Then the last bits for the fuel filter came in from Finish Line factory so we mounted that.  Just sheet metal screws for now but when we strip the shell for paint we’ll drill holes for threaded inserts which we’ll install after the paint has cured. That way the holes will be protected. 
_________________ Paul Eddleston TIM Team Illuminata Motorsport http://www.teamilluminata.com
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team illuminata
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Post subject: Re: Audi UR Quattro Rally Build Posted: Thu Dec 17, 2020 9:08 am |
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I sprinkle rubber on my Cherios |
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Joined: Wed Jun 01, 2011 4:55 am Posts: 416
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Week 10 of the Storage Unit Rally Car Build Inspired by our success with the dash fasteners we moved on to something that has been troubling us for a while, the PCV system. We’d like to keep the engine as stock as possible for now as we don’t want to complicate getting an engine we are unfamiliar with running well after it has been idle for who knows how many years. So we think we’d like to keep the PCV system intact as it came from the factory. This was complicated by the fact that we know nothing of the mysteries of PCV and that part of it connects into the intake manifold; the stock intake manifold. Undaunted we dug through our 300 boxes and pulled out anything that looked like it might be part of a PCV system.  We thought it good insurance to replace all the weird bits that weren’t just pipe so we went to our friends at Pelican Parts.  We offered up the bits that went around the back of the engine but it was clear that our radiator was in the way of a straight shot forward. So out with the pipe cutter!   And added a length of flexible hose. It fits now.  Once passed the radiator we aimed it at the intake manifold behind the throttle body like the stock maniold and used a piece of clear hose for now. We will need to take the manifold off to either weld on a bung or tap it for a fitting of some sort. Next time the engine’s out perhaps. 
_________________ Paul Eddleston TIM Team Illuminata Motorsport http://www.teamilluminata.com
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team illuminata
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Post subject: Re: Audi UR Quattro Rally Build Posted: Thu Dec 24, 2020 8:13 am |
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I sprinkle rubber on my Cherios |
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Joined: Wed Jun 01, 2011 4:55 am Posts: 416
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Storage Unit Rally Build Week 11 - Diverter Valve & Door Handles Diverter Valve Our new diverter valve arrived while we were playing with the PCV system so we slapped that in too, upside down at first!  Fortunately, it sits directly over the turbo pipe into the intercooler  But we will need to weld on a bung to attach it. No welding in the storage unit though.  Door Handles We were told to get a handle on things so we pulled these out of a big blue box.  They go on the doors. Might not seem like a big deal But it’s been a real PITA to constantly reach in through the window aperture to pull the interior door handle. This will make storage unit life much more palatable. If we can fit them. We again went to the parts diagrams to see what was needed.  Initially it didn’t look promising as we seemed to be missing some actuator rods. Specifically, #8 and #9 but when we looked inside the doors we found both #8s still attached to the lock mechanisms.  Also, it turns out the missing #9 operates the lock so we’ll get one of those later as we won’t be needing to lock it for quite a while. The handles themselves cleaned up very nice and we had all the bits. The driver’s side lock did give us a scare as it appeared it may have been re-keyed at some point because we could not get it to turn. A bit of WD40 freed it up though so we slapped them on.  The actuator rods were a bit fiddly but they are now on and the doors work. Nice! 
_________________ Paul Eddleston TIM Team Illuminata Motorsport http://www.teamilluminata.com
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team illuminata
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Post subject: Re: Audi UR Quattro Rally Build Posted: Thu Jan 07, 2021 6:40 am |
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I sprinkle rubber on my Cherios |
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Joined: Wed Jun 01, 2011 4:55 am Posts: 416
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Storage Unit Rally Car Build - Week 13: Axels & Heater Lines AXLES One day we are going to find a new building and will have to push this thing back out and into the trailer. With the axles out the wheel bearings flop about so we didn’t want to struggle with it again like we did, pushing it in. We decided now was a good time to reinstall the axles, even though we haven’t refurbished them yet.  Don’t worry, we cleaned them up a bit. We’re not peasants. When we dug them out of hiding it soon became apparent that there were two long ones and two shorter ones. But where did they go, front and rear, left and right, where? It turns out, opposite corners!  We’re sure there’s a good reason but just for giggles we did try to install one in the wrong place, just because, well, we’re idiots to be honest. It was too long.  HEATER PIPES The 45* bends we were waiting for from Pegasus Racing came in so we got to finish heater pipe installation.  We’ve also located a brand new double grommet for the bulkhead!  
_________________ Paul Eddleston TIM Team Illuminata Motorsport http://www.teamilluminata.com
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team illuminata
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Post subject: Re: Audi UR Quattro Rally Build Posted: Thu Jan 14, 2021 7:17 am |
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I sprinkle rubber on my Cherios |
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Joined: Wed Jun 01, 2011 4:55 am Posts: 416
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Week 14 of the Storage Unit Rally Car Build IACV (Idle Air Control Valve) Yep, we’re now struggling to find things we can install while working in the storage unit. Picking at straws so to speak. Next on our list is therefore the idle air control valve. IACV. If you don’t already know, this ECU controlled valve bypasses the throttle at idle to allow it to, well, idle. Of course, with our fancy aftermarket intake manifold it won’t just bolt back in place. There is a connector for it at the back of the manifold be we’ll still have to tee into the intake tract before the throttle at some place. Here’s the valve with its rubber mounting ring and the nifty bracket that it sits on.   It is quite heavy so we think we should try to mount it using the OE bracket if possible. The inlet to the manifold is towards the back directly underneath, but whatever the IACV mounted off before is no longer apparent. So, we contrived a bracket extension off the engine mount arm as there were already three threaded holes in that. Engage CAD design mode.   We’re not really setup to make this in our storage unit so we’ll either make it later or outsource it. The inlet is a straight-ish shot to the back of the intercooler end tank but we’ll need to weld a bung on for it so, job stopped! SEALS Our searching through various boxes for various parts revealed the window and aperture seals so we decided to take inventory and install some because, well, we’re running out of things we can do and we have to keep moving forward somehow. Door seals  Windshield seal  Under hood cowl seal   Trunk seal  The rest of the window seals are already on the respective windows hidden away, somewhere. These pieces seem to be still in good shape and were surprisingly satisfying to install. 
_________________ Paul Eddleston TIM Team Illuminata Motorsport http://www.teamilluminata.com
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team illuminata
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Post subject: Re: Audi UR Quattro Rally Build Posted: Thu Feb 18, 2021 9:34 am |
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I sprinkle rubber on my Cherios |
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Joined: Wed Jun 01, 2011 4:55 am Posts: 416
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Week 17 of the Storage Unit Rally Build: A Sharp Intake of Breath We’ve been back and forth on what to do about an intake system for the car for ages. We’d like to have our cake and eat it too but we just can’t see a way to get there. This is what we’d like to have:   As used on the works rally cars. It looks iconic and sucks air from the high pressure cowl area where, conveniently, there are louvers in the hood above for that very purpose. There are a few problems with this. Firstly we have a MAF sensor to incorporate in the intake track, ideally in the stock location as we have an aftermarket U shaped intake tube that houses connections for all kinds of other bits and pieces that we need. This really doesn’t mate up to that.  Secondly, if we did this it really would have to be made of carbon Kevlar to pass muster and making one from scratch would be very expensive and time consuming. You can, in theory, buy one but we’ve heard it’s of dubious quality and it still wouldn’t mate to our MAF sensor. We tried prototyping an alternative route to the cowl that goes down the bulkhead to an existing 3” hole before doing a 180 into the passenger compartment and back up through another existing hole in the cowl. We think we could terminate this into an oval shaped pancake filter with a lid. It would probably work and we think we could make it look half decent but our fear is that it would just look like a poor substitute for the original.     We could just whack a bloody great cone filter on the end of the MAF sensor and declare “job done” but there are a few problems with that too. It would be sucking air from right next to the turbo and also be right under the hood louver that lets hot air out of the engine bay and, not great, water in. So we dismissed this too. Here it is mocked up with a small filter.    We looked at modifying some OE intake boxes but they don’t seem to be suitable either.  So we’ve settled. Settled on another U bend with a cone filter behind the headlight. This is not under the louver so should stay dry and it gets a good cold air feed from the grill and light surround. We also think we can shield it from the engine bay quite easily and, although it is a bit rigged it will hardly be visible so it doesn’t matter if it looks it.    If nothing else it will do to get the car running. Maybe we will revisit this later, or not.
_________________ Paul Eddleston TIM Team Illuminata Motorsport http://www.teamilluminata.com
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M. Kelty
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Post subject: Re: Audi UR Quattro Rally Build Posted: Wed Mar 10, 2021 10:33 pm |
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I sprinkle rubber on my Cherios |
Joined: Sun Sep 24, 2006 1:53 pm Posts: 380 Location: middle east of the USA
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Looks Awesome! Keep Crackin !
_________________ 90' 3B Cq, Hy35 86' 951 80' Scirocco, 8v GTI power 85’ GTI hillclimber (proven slow :)
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team illuminata
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Post subject: Re: Audi UR Quattro Rally Build Posted: Thu Apr 01, 2021 9:06 am |
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I sprinkle rubber on my Cherios |
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Joined: Wed Jun 01, 2011 4:55 am Posts: 416
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Prepping for Custom Stainless Exhaust and Skid Plat Design We are honored to have a friend of ours agree to build us an exhaust. It’s going to be 3” stainless steel with one muffler at the rear and as similar looking to the works cars as possible. Of course, that meant we had to build a skid plate! Well, not exactly but we did need to see how much room we would have around it so we mocked one up. First the rear support bar which spans the chassis rails behind the gearbox. We used some rather flimsy aluminum tube we had lying around which made it really easy to flatten the ends.   Our surrogate 3” exhaust tubing fit through but it might need to be lower.  Next, we turned our attention to the front support. We thought we would see if we could mock up a reasonable facsimile of the works support using PVC conduit, even though that would be a little larger diameter than the steel tube we’d ultimately be using. How hard could it be?       Not bad eh?   Next, we need an actual plate. Fortunately, we are a Corbeau seats dealer and their seat boxes are perfect for mocking up skid plates. Our plan was to try to replicate the molded Kevlar are whatever exotic material this one was made from, but in aluminum plate. This might be a three or even four Hobnob project!  Well, you don’t know until you try so we put the kettle and our thinking caps on and had a Hobnob. First, we made a masking tape mold off of our 1:18 model. Then we put that on the photocopier and hit x18! (no, we didn’t)  As convoluted as the works plate appears, if you study the it carefully you can make out many flat looking facets to it. Most obvious is the center section that is about two feet wide. We realized that if we took a long piece of box this wide and put two bends in it we would have the essential structure down. Moreover, if we weld some 2” wide rims on it might look quite similar. So that’s the plan.     We were pretty happy with this so far and decided that maybe this idea had some legs. We pushed on with mounting the cardboard plate to the PVC support bars so we could remove the box and axles stands. To do this we made some clips out of some thin aluminum sheet and bent them around the bars. They worked rather well unless there’s a slight breeze or somebody sneezes too closely!     So that was the basic structure sorted. Now we just needed to widen it; and form the upturned sides! A bit more Corbeau cardboard and loads of Hobnobs and Yorkshire tea later we had this:       Lovely. Right; what shall we work on next? Mud flaps? First, we’ll have to put the kettle on! 
_________________ Paul Eddleston TIM Team Illuminata Motorsport http://www.teamilluminata.com
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team illuminata
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Post subject: Re: Audi UR Quattro Rally Build Posted: Thu Apr 15, 2021 7:33 am |
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I sprinkle rubber on my Cherios |
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Joined: Wed Jun 01, 2011 4:55 am Posts: 416
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The car took a big leap forward recently and, as a result, we are now exhausted.  We asked our friend Scott Banes if he’d like to build us an exhaust and we were honored that he said yes. Scott is a local rallycross and rally competitor who has owned about a gazillion Subarus and we’ve always been impressed with the work he’s done on them. We thought it would be good for him to glue metal together on something else for a change. Plus, his shop is only about 30 minutes from ours so it was an easy tow. He only had the car for the weekend too which was great. Beforehand we talked bout trying to mimic the Group B cars exhaust as much as practical without going nuts. This meant a 3” stainless with one back box but we also wanted to try and incorporate a catalytic converter. After showing Scott all the pictures we had he liked the idea of keeping the down pipe and wastegate dump separate till under the car and thought he could even incorporate the removable plate some of the works cars had and the muffler support bracket, like these:  We left him too it. It was a tight squeeze but he nailed it. The works cars had an enlarged transmission tunnel so their exhaust could go over the axle instead of under it. We gave Scott permission to BFH a bit more room for the cat if he needed to be we didn’t want to have to refabricate the tunnel. As you can see he managed to get both the cat and the extra pipe in, though we have no idea what we’ll do with that hole in the dump pipe.  He would have pulled off the muffler bracket to but didn’t have any suitable rubber bushings to hand so rigged something up for now. We’ll come up with something later, hopefully.  We were very pleased with the attention to detail Scott took with the way the exhaust exits the back of the car. Both the location and angle of the tip are perfect.   Now, if we could just get him to help with the rest of the car! 
_________________ Paul Eddleston TIM Team Illuminata Motorsport http://www.teamilluminata.com
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