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  1. #1
    Veteran Member Four Rings lunamarA4's Avatar
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    My 2002 S8 build

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    Starting this thread has been on my to do list for over a year. But I guess better late than never.

    This model has been on my wish list for as long as I can remember. I have been drooling over this flagship even before seeing it in action in the movie Ronin...but that started an itch that took 19 yrs to drooling.

    I have been an active member here since the purchase of my brand new 2003 Amulet Red B6 sedan and 2 B6 Avants.
    The sedan is long gone and so is my stock ultasport Avant but the fully built white Avant will remain most likely with me for yrs to come. It has kept me busy for almost a decade with constant updates and upgrades but I think I am 95% happy with it...so it was time for a new project...so let's get back on topic.

    I have search for months for a clean D2 S8...and I came across an ad online of a small dealer selling one with all the options I wanted... Specifically black alcantera Recaro seats and solar sunroof.

    The problem was it was in Massachusetts and I was in San Diego, CA and had no time to fly out to inspect the car in person.

    The dealer was courteous to supply a detailed history and video of cold start and walk around...so I thought it be a sure thing and pulled the trigger as no red flags showed....as time showed it was my mistake to trust a $&@# dealer....but in the end the fault lies with me for not getting at least an independent mechanic to inspect the car prior...but that's water under the bridge.

    N e way ...the car was shipped mid January 2017 and I was like a little kid on Christmas morning awaiting the arrival my gift to myself.

    The car looked great for a 2002. I new I would need to do some respray of the bumpers and paint correction eventually to get it to the level of my Avant...that was always calculated into the budget of this built....what was not became apparent immediately when the transport driver started the engine to back it off the rig.



    I felt horrified..."What in the world!!!...this thing sounds like a tractor!"

    Of course I immediately got my Vag cable out to scan for codes and all codes pointed to a bad cat....which was a bit of a relief as I had plans for a custom SS exhaust and maybe high flow cats as well...which this development secured that as definite must To do list addition. But the sound in itself made me thing there must be and exhaust leak as well and the smell in the engine bay of exhaust fumes confirmed those notions.

    The first drive was spectacular for me... coming from driving/owning only turbo cars this was a completely different animal. I loved the response, the power curve, the sound (once I got over the bad cat) ...the D2 made me forget all about the negative initial introduction. It handled great and was so stable for such a big car. But there was work to be done and I had definitely a steep learning curve ahead of me.
    Steering wheel
    and
    Wheels 4 SALE
    RafE |2004 BT White A4 Avant|
    RafE |2002 S8 - under the knife - currently undergoing brakes overhaul|

  2. #2
    Veteran Member Four Rings lunamarA4's Avatar
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    Feb 26 2004
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    lots of tools and spare parts
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    Surprisingly the S8 passed SMOG with flying colors and next on the list was the long awaited (unfortunately post purchase inspection). Took it to a local shop specializing in Audi's and VW's and we got it in the air.
    It became apparently very quickly that I was in trouble on another account...I failed to realize for some short minded reason that not the entire car is made from the awesome aluminum that space frame chassis is and practicaly the subframes and all suspension components..bolts etc are rusted to $#@&!!!!
    Their advise..drive it and when something brakes with it leave it at the closest junkyard or sell it ASAP.

    But I was up to the challenge.

    Sourced out mint subframes and any discontinued..no longer in production parts from a CA junkyard S8 and the rest..bolts bushings ..what not thorough an East Coast Audi dealer acting as an intermediary as 90% of those parts had to come straight from Germany.

    This gave me the hope and the ability to see the light at the end of the tunnel and believe that I will be able to accomplish what I have in store still for this car.
    Steering wheel
    and
    Wheels 4 SALE
    RafE |2004 BT White A4 Avant|
    RafE |2002 S8 - under the knife - currently undergoing brakes overhaul|

  3. #3
    Veteran Member Four Rings lunamarA4's Avatar
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    Feb 26 2004
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    With the suspension parts weeks if not months away from being compiled it was time to tie up some loose ends.

    First thing on the agenda was the engine. Not really knowing the true past maintenance it was time to go through it with fine-tooth comb.

    So the timing belt, water pump, all the seals and gaskets and chain tensioner for cyl 1-4 were replaced. Also replaced the engine snub mount, all accessible coolant hoses and coolant reservoir and all the liquids were flushed.
    In the process got some of the billet goodies from GruvenParts to replace the broken OEM plastic ones...linkage arms/pivot levers/ oil filter housing and dipstick handle) you can see part of them installed in the picture below.

    Actually the pivot levers had to be updated as they didn't work initially like the OEM parts.

    Here is a link for those interested
    http://www.gruvenparts.com/shop-by-car/audi/a8-s8




    Slowly getting is looking closer to how clean my Avant engine looks like.

    In addition to the billet pieces got billet engine oil, power steering and coolant caps, as well as all vacuum lines were updated.

    JHM supplied the intake spacers and lightweight crank pulley.

    https://jhmotorsports.com/jhm-intake...ad-40v-v8.html

    https://jhmotorsports.com/products/e...g-belt-v8.html

    Also the finish on the intake manifold was peeling so I stripped it and polished it fast with a wire brush and my drill. Might eventually powder coat it...once I settle on the color.

    (I wish I took pictures along the way...but will try to update the thread with more engine bay pictures with time)
    Last edited by lunamarA4; 02-04-2018 at 01:39 AM.
    Steering wheel
    and
    Wheels 4 SALE
    RafE |2004 BT White A4 Avant|
    RafE |2002 S8 - under the knife - currently undergoing brakes overhaul|

  4. #4
    Veteran Member Four Rings lunamarA4's Avatar
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    Since suspension pieces were still trickling in...and the front bumper was off it was perfect time to upgrade the lighting.

    Installed LED bulbs throughout the interior and an LED strip in the trunk to easier visualize the deep trunk at night.
    http://deautokey.com/product/univers...all-car-models

    As for the headlights and fog lights follow the link below for DIY thread posted by me few months ago....
    http://www.audizine.com/forum/showth...the-D2-housing

    Last edited by lunamarA4; 02-04-2018 at 01:39 AM.
    Steering wheel
    and
    Wheels 4 SALE
    RafE |2004 BT White A4 Avant|
    RafE |2002 S8 - under the knife - currently undergoing brakes overhaul|

  5. #5
    Veteran Member Four Rings lunamarA4's Avatar
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    Feb 26 2004
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    lots of tools and spare parts
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    San Diego, CA
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    Due to space and equipment constraints...the subframes and most of the suspension components were taken care of by a shop.

    They also installed my non rusty downpipes sourced along with the subframes from a CA donor car and Magnaflow cats paired with new O2 sensors. As it sits they still connect to the rusty stock exhaust...which hopefully will be updated in the next month or two with custom quad exhaust.
    Steering wheel
    and
    Wheels 4 SALE
    RafE |2004 BT White A4 Avant|
    RafE |2002 S8 - under the knife - currently undergoing brakes overhaul|

  6. #6
    Veteran Member Four Rings lunamarA4's Avatar
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    lots of tools and spare parts
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    San Diego, CA
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    Now that the "new" subframes were in it was time to address the stance.

    I really wanted the KW V2 coilovers but as my luck goes I was just late to the party and they too became discontinued.

    I settled for the V1 variant which I found a great deal on on this site.
    https://www.cheap-coilovers.com/shop...s8-9834c1.html







    So great to see no rust on the hardware or the suspension components..all bolts, control arms, suspension and subframe bushings are brand new and OEM.

    Just to compare to a year ago



    What a difference!!! Puts a smile on my face!
    Last edited by lunamarA4; 02-04-2018 at 02:29 AM.
    Steering wheel
    and
    Wheels 4 SALE
    RafE |2004 BT White A4 Avant|
    RafE |2002 S8 - under the knife - currently undergoing brakes overhaul|

  7. #7
    Veteran Member Four Rings lunamarA4's Avatar
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    Feb 26 2004
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    lots of tools and spare parts
    Location
    San Diego, CA
    Items for Sale

    Could not resist the one time opportunity to take a picture

    Steering wheel
    and
    Wheels 4 SALE
    RafE |2004 BT White A4 Avant|
    RafE |2002 S8 - under the knife - currently undergoing brakes overhaul|

  8. #8
    Established Member Four Rings JD S4's Avatar
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    May 07 2016
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    Boulder, CO

    Awesome!


    Sent from my
    '11 S4 with all the mods

  9. #9
    Veteran Member Four Rings lunamarA4's Avatar
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    Feb 26 2004
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    lots of tools and spare parts
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    Both front axles needed to be replaced and the driver side hub bearing.
    But I ran into a problem separating the bearing and the hub..even a shop could not get it off and in the process got ruined so both new bearing and hub we're installed on the driver side.

    Last edited by lunamarA4; 02-04-2018 at 02:32 AM.
    Steering wheel
    and
    Wheels 4 SALE
    RafE |2004 BT White A4 Avant|
    RafE |2002 S8 - under the knife - currently undergoing brakes overhaul|

  10. #10
    Veteran Member Four Rings lunamarA4's Avatar
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    Feb 26 2004
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    lots of tools and spare parts
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    Decided to place dress up and test fit my second set of wheels from my B6 Avant that I am selling



    ****This is prior my coilovers installation.
    Steering wheel
    and
    Wheels 4 SALE
    RafE |2004 BT White A4 Avant|
    RafE |2002 S8 - under the knife - currently undergoing brakes overhaul|

  11. #11
    Veteran Member Four Rings lunamarA4's Avatar
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    Feb 26 2004
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    On to brakes.
    Man did they needed some love...the driver side brake line was so rusted that it got fussed to the nut...the only way to remove it was to twist the whole assembly which ruined it... hoping my source in Germany will be able to source out a custom made to order one... as you might guessed it...it is no longer available 😭👿😤

    But Centric was able to rebuild all the calipers and this is what I received this week...so it made me forget for a bit that the darn brake line is keeping me from enjoying my car



    All new hardware.... powder coated gloss black

    ...ready for installation with new brake lines



    And let's not forget all the goodies from AdamsRotors



    Still awaiting the front caliper stickers
    Steering wheel
    and
    Wheels 4 SALE
    RafE |2004 BT White A4 Avant|
    RafE |2002 S8 - under the knife - currently undergoing brakes overhaul|

  12. #12
    Veteran Member Four Rings lunamarA4's Avatar
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    Feb 26 2004
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    In the meantime the new set of shoes is getting powder coated and the tires are on order in 255/40/19 size.

    Only thing that I'm still waiting on is the driver side brake line
    Steering wheel
    and
    Wheels 4 SALE
    RafE |2004 BT White A4 Avant|
    RafE |2002 S8 - under the knife - currently undergoing brakes overhaul|

  13. #13
    Established Member Two Rings
    Join Date
    Aug 26 2011
    AZ Member #
    80337
    Location
    Rutland, Vermont

    Great work man! If i send you a PM, id love to pick your brain about the process and prices of what you got done with the brake calipers from Centric.. i think that same type of refurb is in my future with my D2.


    Sent from my iPhone using Tapatalk
    2004 .:R32 // 2001 S8

  14. #14
    Active Member One Ring
    Join Date
    Jan 24 2018
    AZ Member #
    412943
    Location
    San Diego, CA

    Your patience and dedication are impressive, it should pay up with a great car.

  15. #15
    Veteran Member Four Rings Street Nasty's Avatar
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    Jan 20 2009
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    My Garage
    B9 RS5
    Location
    NYC
    Items for Sale

    Great work on restoring the car. You should look into the the brake block on quattroworld someone was custom fabbing. Maybe you can find the cad file. It helps a ton with pedal feel.

    Sent from my Firefly phone.

  16. #16
    Veteran Member Four Rings lunamarA4's Avatar
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    Feb 26 2004
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    lots of tools and spare parts
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    Quote Originally Posted by Street Nasty View Post
    Great work on restoring the car. You should look into the the brake block on quattroworld someone was custom fabbing. Maybe you can find the cad file. It helps a ton with pedal feel.

    Sent from my Firefly phone.
    Already part of that group buy. Definitely can't wait to see improvement in pedal feel
    Steering wheel
    and
    Wheels 4 SALE
    RafE |2004 BT White A4 Avant|
    RafE |2002 S8 - under the knife - currently undergoing brakes overhaul|

  17. #17
    Veteran Member Four Rings lunamarA4's Avatar
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    Feb 26 2004
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    lots of tools and spare parts
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    Quote Originally Posted by osin34 View Post
    Great work man! If i send you a PM, id love to pick your brain about the process and prices of what you got done with the brake calipers from Centric.. i think that same type of refurb is in my future with my D2.


    Sent from my iPhone using Tapatalk
    Let me know what questions you have...
    Steering wheel
    and
    Wheels 4 SALE
    RafE |2004 BT White A4 Avant|
    RafE |2002 S8 - under the knife - currently undergoing brakes overhaul|

  18. #18
    Established Member Two Rings
    Join Date
    Aug 26 2011
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    Rutland, Vermont

    Quote Originally Posted by lunamarA4 View Post
    Let me know what questions you have...
    PM sent! thanks again.. also just posted on quattroworld to see if i can get in on that group buy before it's too late


    Sent from my iPhone using Tapatalk
    2004 .:R32 // 2001 S8

  19. #19
    Senior Member Two Rings SindreVjohnsen's Avatar
    Join Date
    Dec 21 2014
    AZ Member #
    304645
    Location
    Norway

    Nice


    Sent from my iPhone using Audizine
    -Artic White Avant, 2.7 quattro

    - Audi A6 Avant , Shadow Line , ABT kit. (sold)

  20. #20
    Veteran Member Four Rings lunamarA4's Avatar
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    Feb 26 2004
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    Quote Originally Posted by SindreVjohnsen View Post
    Nice


    Sent from my iPhone using Audizine
    Little update

    So I started playing with wheel options...a little too hopeful 19x9.5 et 20







    Missed it by just a hair lol




    Back to drawing board
    Last edited by lunamarA4; 02-13-2018 at 05:33 AM.
    Steering wheel
    and
    Wheels 4 SALE
    RafE |2004 BT White A4 Avant|
    RafE |2002 S8 - under the knife - currently undergoing brakes overhaul|

  21. #21
    Veteran Member Four Rings lunamarA4's Avatar
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    Feb 26 2004
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    Since I like the FAT 5 OEM look ... I decided to stay with the TSW Bristol Wheels but get them in silver and 19x9.5 et35 Hub 72mm - square set up

    Since they only come in Mirror Cut Face it was time for picking a powder coat color


    Stay tuned
    Steering wheel
    and
    Wheels 4 SALE
    RafE |2004 BT White A4 Avant|
    RafE |2002 S8 - under the knife - currently undergoing brakes overhaul|

  22. #22
    Veteran Member Four Rings lunamarA4's Avatar
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    The 19x9.5 et35 has a much better fit




    Steering wheel
    and
    Wheels 4 SALE
    RafE |2004 BT White A4 Avant|
    RafE |2002 S8 - under the knife - currently undergoing brakes overhaul|

  23. #23
    Veteran Member Four Rings lunamarA4's Avatar
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    Feb 26 2004
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    Back from the shop....ahhh no more shiny mirror finish

    HELLO CRUSHED SILVER

    I know it looks so so in the poor light and no tires and off road truck suspension...but I think it will look pretty cool once all done



    Last edited by lunamarA4; 02-13-2018 at 05:46 AM.
    Steering wheel
    and
    Wheels 4 SALE
    RafE |2004 BT White A4 Avant|
    RafE |2002 S8 - under the knife - currently undergoing brakes overhaul|

  24. #24
    Established Member Two Rings
    Join Date
    Aug 26 2011
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    Location
    Rutland, Vermont

    can't wait to see these mounted! some of your picture links don't work on tapatalk app.. but very well could be my phone, just a FYI


    Sent from my iPhone using Tapatalk
    2004 .:R32 // 2001 S8

  25. #25
    Veteran Member Four Rings lunamarA4's Avatar
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    Feb 26 2004
    AZ Member #
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    My Garage
    lots of tools and spare parts
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    Yes
    I think once u log in on your computer you should be able to see them
    Steering wheel
    and
    Wheels 4 SALE
    RafE |2004 BT White A4 Avant|
    RafE |2002 S8 - under the knife - currently undergoing brakes overhaul|

  26. #26
    Senior Member Two Rings SindreVjohnsen's Avatar
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    Dec 21 2014
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    304645
    Location
    Norway

    Haha «close» one
    Getting mine today , 10.5" et 30 🤷🏻*♂️
    Will be fun too see the fitment


    Sent from my iPhone using Audizine
    -Artic White Avant, 2.7 quattro

    - Audi A6 Avant , Shadow Line , ABT kit. (sold)

  27. #27
    Veteran Member Four Rings lunamarA4's Avatar
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    Feb 26 2004
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    Quote Originally Posted by SindreVjohnsen View Post
    Haha «close» one
    Getting mine today , 10.5" et 30 🤷🏻*♂️
    Will be fun too see the fitment


    Sent from my iPhone using Audizine
    What are you fitting them on? Which wheel?
    Steering wheel
    and
    Wheels 4 SALE
    RafE |2004 BT White A4 Avant|
    RafE |2002 S8 - under the knife - currently undergoing brakes overhaul|



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