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Audi UR Quattro Rally Build

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Fri Mar 23, 2018 5:40 am 
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Looks amazing
All the body work time was worth it
Where did you get the dash? James?


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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Fri Mar 23, 2018 6:12 am 
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Afterthought wrote:
Looks amazing
All the body work time was worth it
Where did you get the dash? James?


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James.

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Sun Apr 01, 2018 4:41 pm 
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This concept of refurbishing parts then bolting them to the unpainted shell is working out well as we have already discovered a few things we need to mod and are accumulating quite a parts list too.

We got our first batch of parts back from powder coating:

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And wasted no time attaching some of them to the car. Front sub=frame for instance:

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We also received a Sparco battery cut-off for the dash:

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Our friend Paull is concurrently building an RS200 replica with a Focus RS crate engine. He brought over his superfluous factory intercooler to see if it might work for our application. Maybe:

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We finished the refurb on the steering column but it is going to need a bushing sleeve replaced before being put into actual service. However, this didn’t stop us bolting it up along with the refurbished pedal assembly:

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We thought our pedal assembly was in pretty good shape, until we took the over-center spring apart to clean it:

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Add that to the parts list. Stll, it didn’t stop us bolting it to the car:

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We also spent a bit of time prepping some parts for plating. We are having this lot zinc dichromated so they need sand blasting first. It was suggested filling the cylinder bores with hot glue so they wouldn’t get sand blasted so we gave it a try.

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We took the opportunity to test fit the dash as we suspected it would interfere with the steering column. We were not wrong. There’s a reason for that cutout after all:

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We plan to continue to assemble the car this coming week so look for an update soon.

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Sun Apr 01, 2018 6:31 pm 
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That dash.... so cool! I wish I had one .
Looks like you guys are really into the fun part of the build now .
I found myself wishing I had modified some things in the engine bay before I had painted it , next carnwill probably take your approach and mock up first .

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Mon Apr 02, 2018 4:36 am 
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The weave on those seats look so period correct! Love it. And that dash is gonna be legit too!

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 Post subject: Audi UR Quattro Rally Build
PostPosted: Tue Apr 03, 2018 6:32 am 
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Its just me but if I had the front end you have i would go for a bigger intercooler core and one that is all metal and eliminate the potential for leak with the clamped plastic end tanks.
For reference, an a stock front end with AAN and V-belts in urq I was able to fit a 27 x 9 x 2.5" core in my car which looks to be about the same size as that Focus unit. Running V-belts gave me more space up top than serpentine would have. Maybe that into will help for your selection.
With your grill and front end you should be able to go up to 3" or maybe even 3.5" deep and as tall as you want which gives you way more CFM. Places like Garrett, Vibrant , or Treadstone have some good cores and can weld on the end tanks if you specified size .
If you run single pass with a forward intake manifold and that front end, it gives you lots of choices. jealous!!
Some pics from the internet
Image
Image

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Tue Apr 03, 2018 7:45 am 
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Thanks. The pictures are great. We are thinking of going as tall and as thick as possible and assume we will end up with a custom one. Just trying a few existing ones on for size right now though.

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Tue Apr 03, 2018 8:02 am 
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team illuminata wrote:
Thanks. The pictures are great. We are thinking of going as tall and as thick as possible and assume we will end up with a custom one. Just trying a few existing ones on for size right now though.

About the 7th post down on this page has some good pics as well. I think there were some dimensions somewhere.
I modeled my linkages and belt tensioners off this kind o f
viewtopic.php?f=6&t=12422&start=150

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Wed Apr 04, 2018 8:02 am 
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I have to agree, that RS200 intercooler looks tiny, but than again it was only a 1.8L engine.
With the rally grille you have ton of room, take advantage of that.

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Wed Apr 04, 2018 8:10 am 
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ralleyquattro wrote:
I have to agree, that RS200 intercooler looks tiny, but than again it was only a 1.8L engine.
With the rally grille you have ton of room, take advantage of that.


The bigger the better, right?

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Wed Apr 04, 2018 6:36 pm 
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I just got my SQ replica IC from 2B and its HUGE!!

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85 Ur-q - Euro with 3B
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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Wed Apr 04, 2018 7:16 pm 
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ralleyquattro wrote:
I just got my SQ replica IC from 2B and its HUGE!!


Pics?

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu Apr 05, 2018 5:42 pm 
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TOO MANY FRONTS!

What do we mean by “fronts”. Well, we have opened up quite a few areas of work on the car, none of which seem to be nearing completion: namely:
• transmission,
• plating
• pedals
• dash
• shifter

We have power washed the transmission and replaced axle seals but we broke a tab off the rear output unit and only just found a spare transmission to steal one off. Now we will disassemble that and replace both seals. Fortunately the bearing in this one is in great shape so it actually saved us some money and time.

Image[/url]

Still have to clean the trans and replace the input seal. Then install the shift linkage we recently refurbished.

Along with the calipers we prepped for plating we also have dozens of fasteners and brackets to re-plate. To help with the cleaning process we bought a vibrating parts cleaner from Harbor Freight. We are still learning what media works best for what degree of rust etc.

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We did make some progress with the shifter in that we managed to disassemble it. Without breaking anything either!

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The reverse lock-out tab is bent but otherwise it’s OK. We ordered a short shift kit from 034 Motorsports for it too 


We laid down some plywood floorboards after installing the pedals. The floor was very uncomfortable to kneel on and our work boots made it dirty. This will be a lot more convivial.

Image


We still need to find the accelerator pedal, get the dash to fit over the steering column and also fill it with gauges and switches.

Lots to do!

Image

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Fri Apr 06, 2018 6:20 am 
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Great idea on the plywood! Nice progress.

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Fri Apr 13, 2018 3:14 pm 
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We made quite a lot of progress this week but it doesn’t feel like it. Perhaps because we didn’t get to actually bolt anything to the car. What we did do was finish prepping the transmission. We replaced the rear coupling and seals with a non-broken version, cleaned and painted the case, installed new drain and fill plugs, replaced the input shaft seal and installed the mounts and brackets. Mounts are 034 Motorsport in Delrin.

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People keep telling us we really need to run with the big, heavy rubber damper mounted to the back of the transmission as Audi intended but we’d really rather leave it off. Are we nuts?


We also managed to recommission our ancient, homebuilt sand blaster and put it to work on some rusty components. Unfortunately, in our excited state, we forgot to take the “before” pictures.

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Next week we hope to modify the dash to fit over the steering column and get some parts plated. We will also look for something to bolt to the car. Exciting!!!!!!!

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Wed Apr 25, 2018 8:48 am 
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Like most car nuts we are easily distracted by shiny things that come in the mail. This week was particularly distracting in that regard:

Clutch bulkhead brace from 034 Motorsports:

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Solid Delrin engine mounts from 034 Motorsports:

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Transmission mounts from 034 Motorsports:

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Image[/url]


Short shift kit from 034 Motorsport (of course):

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We also gave the car its own "woom" to gestate in. Do you think it will be ready in nine months?

Image


Next up. Hacking up the dash to make it fit.

Image

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Wed Apr 25, 2018 2:41 pm 
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Nice. Really liking all the pictures. Can see a lot of time was put in on the small details with how clean the trans is and the new bushings and lines.
Looking forward to see what the powerplant is going to be. I opted to retain my stock URQ trans as well.

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu Apr 26, 2018 6:55 am 
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Afterthought wrote:
Nice. Really liking all the pictures. Can see a lot of time was put in on the small details with how clean the trans is and the new bushings and lines.
Looking forward to see what the powerplant is going to be. I opted to retain my stock URQ trans as well.


Thanks Afterthought. Unfortunately we are being inspired by this build:

http://www.mat.fi/projects/65

it may bankrupt us LOL.

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu Apr 26, 2018 8:15 am 
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That project and yours are both inspiration and I will be doing a build like this soon . The MAT.FI build... I have looked through that build many times and will continue to. So many cool things and the skills are incredible. To explain how cool that build is I'd have to literally invent new words .
On the Cage, did TRF build it to meet a specific specification?

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu Apr 26, 2018 9:33 am 
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Afterthought wrote:
That project and yours are both inspiration and I will be doing a build like this soon . The MAT.FI build... I have looked through that build many times and will continue to. So many cool things and the skills are incredible. To explain how cool that build is I'd have to literally invent new words .
On the Cage, did TRF build it to meet a specific specification?


It's ARA and RA and maybe even NASA compliant as far as I know.

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Tue May 01, 2018 4:18 pm 
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It’s time to make the Group B rally dash actually fit in the car. This is a reproduction panel modelled on an original by a member of the US Quattro community and is beautifully crafted. Unfortutunately they have to be “relieved” to fit round the steering column as the lower return is supplied straight. You can’t just cut it as it would then be too flimsy. An added complication is that we intend to still use the ignition key so we have to make room for the barrel housing too. You can see the interference here:

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That bottom flange needs to follow the curvature of the panel. To do so it needs to be cut, formed and then a bridge piece added to maintain its rigidity. Then we will need to remove some material to clear the lock. We will have to do all this with the gauge panel in place or it will easily distort.

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These fasteners will be replaced with rivets once we are confident everything fits.

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Then we needed to clear the ignition key housing:

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The dash panel is suspended from the dash bar welded between the cage A pillar bars but will need some bracing beneath to stop it swinging back and forth. We fabricated these brackets and used the holes from the old cage to help mount them.

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Done!

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Now to mount some more gauges, fuses and a computer!



Image

(These are just a small selection of the pictures we have taken. You can see all of them at https://flic.kr/s/aHskqskKvZ)

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Thu May 31, 2018 2:18 pm 
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Gauging progress on the Quattro Rally Build.

The dash on the Group B Quattros is somewhat iconic especially the big orange oil light in the middle. For this reason we have been very keen to progress work in this area.



Our large tachometer came without any mounting hardware. It looks like it was designed to mount into a rubber grommet like the Porsche 911 gauges. That was never going to work with the 2mm thick aluminium dash we are working with so we had to get creative. First we tried a large hose clamp but of course it rattled around.



Image





Then we butchered some garage door seal for its rubber and tried that under the hose clamp.



Image



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This worked as the clamp squeezed itself up against the back of the dash but didn’t really look the part. We found a roll of thicker black seal in the back of the shop and sliced that up instead. Success!



Image





Then our missing VDO gauges came in from egauges.com so we mounted them up. The threaded sleeve on these makes installation so much easier than the yoke and thumb nuts of old.



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Our tachometer came without mounting studs but no yoke so we made one.



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Then we just had to put it into the car.



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All it needs now is warning lights and switches, mostly.





We were also very excited to receive a box of metric flange nuts and bolts we found on eBay. These will be very useful.



Image



Yes, we know, we’re nuts!







Image

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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Fri Jun 01, 2018 1:25 pm 
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Great progress! Where did you source the ball/socket joints for the transmission cross-rod?


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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Fri Jun 01, 2018 2:18 pm 
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>>ball/socket joints for the transmission cross-rod

Those look like McMaster-Carr, to me.

Paul, what did you use for the main transmission shift bushing? You look to have something red and shiny there. I've gone thru ~7 of the 034 bushings and have given up with that.

Great build, BTW! I love the wide body kit on the long wheel-base chassis, far more than the shorty.

Thanks, Eric


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 Post subject: Re: Audi UR Quattro Rally Build
PostPosted: Wed Jun 06, 2018 2:08 pm 
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We took our first foray into replating components recently. Many steel components on 80s German cars have a gold finish which was at the time probably cadmium plating. These days, due to EPA regulations, zinc dichromate plating seems to be a better option. You can do it in-house quite easily but the dichromate part is really toxic so we prefer to have it done as far away from our shop as practicable. We have also resisted the temptation to lick the newly finished parts.

First step in the process is to degrease the components and then to remove all the rust by blasting. As we mentioned earlier, we recently recommissioned our home-made sand blaster so used that to blast a bunch of accumulated parts.

Image

Image


We boxed them up and ran them over to Plating Specialists Inc. in Madison Heights. A safe 15 miles from our shop. Two weeks and $240 later WOW:

Image


We couldn’t help but bolt a few components to the car:

Image

Image


We think we might be addicted to zinc dichromate plating now.

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