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MadAudi
09-03-2012, 10:58 PM
With labor day being the unofficial end of summer, it is time to start my new S4 rebuild thread.

The car in question:

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/IMG_0018.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/IMG_0016.jpg

It's a laser red 2000 S4 with 139,000 miles on the clock. I bought it about a month ago for very, very little money. The previous owner had no idea the car was already set with BW K04 Turbo's, New RS4 Clutch, (both to be for sale soon),21 PSI Stage 3- Tune, and rebuilt transmission. That being said, $4K bought the car, given it has some minor cosmetic blemishes, and every warning light possible is on. [wrench]

My general plan for this car is to rebuild it nose to tail, body work first, then suspension and driveline, cleaning up the transmission, fully built engine w/ 2.8 heads, new interior and mild audio system, lots of carbon fiber goodies, and to top it all off....an 034 single turbo system as soon as it becomes available.

After spending the weekend cleaning and organizing my cars new home for the next several months, today was the first day of actual wrench time I have put into the car, so here it does:

Stage 1: Body Work

The car has had a repaint in the past, and poor prep work has started to show. The biggest flaw the car had was rust eating away at the left rear door. First step: cut out offending sheet metal and weld in a proper patch plate.

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00616.jpg

The offending area removed....

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00623.jpg

The new patch welded, hammered, and blended into the door.

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00619.jpg

Another dent pulled and smoothed out, ready for some mudwork.

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00629.jpg

Another angle of the door currently worked on.

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00631.jpg

Trunk de-baged and torn down. Minor rust was repaired/ground down to bare metal. Thankfully it was just surface rust and cleaned up nicely. Minor mud work will be needed.

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00630.jpg

Front bumper removed

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00628.jpg

Minor cracks plastic welded and repaired.

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00625.jpg

Washer nozzle area's prepped for being shaved, hopefully this will clean up the front of the car a little bit!


I ordered some 3M Seam Sealer to seal the weld's on the patch panel, and plan on plastic welding the patch plates on the front bumper tomorrow and getting it prepped for some pimer.

Today's goal: Paint shop in 2 weeks.

Blackstallion
09-03-2012, 11:24 PM
ahh this should be fun. Look forward to watching the build...BTW I love laser red!!!!

evil_s4
09-04-2012, 07:14 AM
subsrcibed and looking forward to the progress. summer is starting to come to a close here in the great north and i will be starting the same thing in the next few weeks. Good Luck!!

Limey
09-04-2012, 07:19 AM
Good looking car, subscribed :)

Der Konig
09-04-2012, 07:25 AM
Way to save a beaut from crashing and burning. Great color and interested to see how it goes. Good luck!

sent with voodoo black magic

SlowRolla
09-04-2012, 07:58 AM
Lookin good!

Corrado
09-04-2012, 08:17 AM
Looks great! How's the interior?

I can't believe you can pick-up an S4 in decent shape for $4k now! (especially with K04s and other doo-dads like you got).

2380S4
09-04-2012, 09:08 AM
Was this on cl? If so nice snag!

boss99er
09-04-2012, 10:41 AM
Hey MadAudi, what did you use to plastic weld the front bumper? I have a few cracks on mine that I'd like to do the same to. Thanks!

SomeDayAS4
09-04-2012, 10:55 AM
delete lower moldings... didnt read if you were going to or not bur it will clean it up nicely

MadAudi
09-04-2012, 11:08 AM
Hey MadAudi, what did you use to plastic weld the front bumper? I have a few cracks on mine that I'd like to do the same to. Thanks!

I have a plastic welding gun and filler so I am actually melting the ABS back together.

AVier
09-04-2012, 11:19 AM
Nice work[wrench]

boss99er
09-04-2012, 12:18 PM
I have a plastic welding gun and filler so I am actually melting the ABS back together.

Ahh nice! I wonder if Harbor Freight has anything like that. Once you melt it together, what do you fill it with? More ABS plastic? Body filler?

hendrj5689
09-04-2012, 12:22 PM
Subscribed! Looking forward to see the progress!

FLIPFLOPS4
09-04-2012, 02:15 PM
Good luck with the build, looks like you have the necessary space and tools to complete the job. Interested in taking that RS4 clutch off of your hands at a reasonable price. Subscribed and looking forward to checking in every now and then on your progress. PM me what you want for the clutch.....

hodrosS42001
09-04-2012, 03:26 PM
Sick project. Sick deal. Keep the updates coming!

MadAudi
09-05-2012, 12:32 AM
Today was another great night in the garage, I got a huge window mounted A/C Unit + My garage is fully insulated = Lot's of motivation to do work!

I focused on the front bumper today, filling in the washer holes and finishing off some of the cracking issues. Pics:

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00633.jpg

One patch panel made

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00635.jpg

Another patch panel made

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00636.jpg

First pass with plastic welder. Went all the way through in order to fill in and create a very strong and thorough bond.

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00638.jpg

Patch filled in.

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00639.jpg

First pass roughly ground down....

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00641.jpg

Finer Sanding...prep for mud.

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00642.jpg

More mud prep.

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00643.jpg

First coat of mud.

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00644.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00646.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00647.jpg

More area's repaired.

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00649.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00651.jpg

Another coat of mud, some sanding and blocking later....no more washer holes!

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00652.jpg

Sanded down and prepped the rest of the bumper.


Tomorrow's goal is to get the rest of the bumper sanded, prepped, masked off, and shot with primer....more updates to come...

MadAudi
09-05-2012, 10:26 PM
Ended up getting some side work to fund the project, so no progress today. Should have the bumper in primer tomorrow morning and can start working on the rest of the shell, rolling the front fenders and evening out some minor dents.

supremedk
09-06-2012, 08:57 AM
Very nice work! i have been wanting to fill delete my headlight washers for a while, looks so clean.

Sour
09-06-2012, 05:05 PM
awesome subbed

Dutchsider
09-06-2012, 05:32 PM
Watching this. Nice work thus far.

034Motorsport
09-06-2012, 05:33 PM
I am jealous of your willingness to do body work!

I got no problem turning my own wrenches, but body work? No thanks! I don't have the patience or the skillz!

Looking forward to this coming together, especially once you get into the motor stuff! [evilsmile]

Dutchsider
09-06-2012, 05:33 PM
I am jealous of your willingness to do body work!

I got no problem turning my own wrenches, but body work? No thanks! I don't have the patience or the skillz!

Looking forward to this coming together, especially once you get into the motor stuff! [evilsmile]

Indeed, body work require tons of expendable materials each time to do something; that and tons of time.

MadAudi
09-06-2012, 11:57 PM
Thanks for all the comment guys!

I was a Master Tech at a mechanical shop that was connected to a body shop, so when it was slow I picked up some tips and tricks for body work from the other fellow Polak working there. It really isn't that bad if you know what your doing and take time in your prep work. Hopefully I can get it into paint next Saturday. With that being said.....


Did some more work tonight. Got the front bumper into primer, blocked it down, and now its ready for the paint shop.

Then I took attention to the front fenders. Pulled out the liners, hammered and dolly'd the fenders flat in prep for some new meaty tires underneath, then sanded them down and gave them a coat of primer. The trunk was to follow. Sanded that down, evened it out, and shot it with primer. Did the same with the upper passenger door, and some other minor area's that needed love on the car. Tomorrow I will block everything that I can down, and while I wait for my seam sealer to show up the car will get further stripped and prepped for paint!

Pics:

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00660.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00662.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00663.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00664.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00665.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00666.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00667.jpg

FLIPFLOPS4
09-07-2012, 07:51 AM
Keep up the good work

ggg20t
09-07-2012, 08:54 AM
This is incredible. I love car restoration. Keep the pictures coming!

JEENYUS
09-07-2012, 10:02 AM
I look forward to this build.

JPM-Engineering
09-07-2012, 10:28 AM
Very nice.. subbed

MadAudi
09-07-2012, 10:16 PM
Did some more work tonight. Blocked out as much of the car as possible, installed the bumper and rear wheels. Waiting on my seam sealer to show up so I can finish the door and send it off to the paint shop for finishing touches and paint!!

Pics:

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00669.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00671.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00672.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00674.jpg

Limey
09-07-2012, 10:31 PM
Coming along nicely

williamr91
09-08-2012, 08:24 AM
Yay quick progress too, I assume this is a evening/weekend job you've been doing.

JDM EJ1 95
09-08-2012, 08:34 AM
nice work adam.

hendrj5689
09-08-2012, 10:44 AM
Looking great! Glad to see lots of progress.

FLIPFLOPS4
09-08-2012, 11:41 AM
Awesome dude, can't believe the amount of work that you've completed in what seems like a short amount of time, can't wait to see it after you get it back from paint

MadAudi
09-08-2012, 02:35 PM
Well there is no turning back now. Did some repairs on a fellow stage 3 S4 today and he ended up buying a few of my K04 goodies! Will have another update hopefully tonight!

MadAudi
09-08-2012, 08:13 PM
Not to big of an update.

Got my seam sealer in, so I sealed off everything that needed to be sealed. At $75 a bottle this stuff aint cheap, but the results are great! Inside and outside got a coat to lock out moisture and prevent rust. Directions say that it cures in 60 minutes, however I was advised by my body guy to let it sit overnight before doing any sanding/mud work.

Some Pics:

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00675.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00676.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00677.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00679.jpg

Tomorrow I will finish the mudwork on the car and block it down again for a final coat of primer. Then it's time to prep all the panels and drop it off at the body shop on Saturday!

ElliottG
09-08-2012, 08:20 PM
Is that just regular seam sealer or some magic stuff? The seam sealer I bought here was definitely not $75 lol. I used the same stuff on the inside of my front fender lips to prevent rust when I painted them...but I didn't know about doing stuff like this.

I'm guessing you're gunna sand the crap out of it? Just surprised that by the time you get it all flat there will still be enough "sealer" there to seal it up...

MadAudi
09-08-2012, 08:30 PM
Is that just regular seam sealer or some magic stuff? The seam sealer I bought here was definitely not $75 lol. I used the same stuff on the inside of my front fender lips to prevent rust when I painted them...but I didn't know about doing stuff like this.

I'm guessing you're gunna sand the crap out of it? Just surprised that by the time you get it all flat there will still be enough "sealer" there to seal it up...

It's 3M two part stuff, yeah $75 a bottle and I had to borrow a special gun and mixing needel's to apply it. It's body shop grade stuff, auto part stores don't carry it, I had to order it from Sherwin Williams auto body supply.The picture makes it look like there is more on there than there actually is, just enough to seal everything up well on the outside. The inside will stay as is.

ElliottG
09-09-2012, 08:31 AM
Yeah I see what you mean now. I'm guessing you're still gunna sand it though? Please take more pics of that area in particular! lol

And are you gunna use a flexible body filler on that area?

MadAudi
09-09-2012, 10:05 PM
Another quick update tonight. Finally finished all the mud work on the car, got everything evened out and initially blocked down. The left rear door is a b*tch to do because its not flat in any way. Shot everything that needed to be shot with primer and I'm letting it dry overnight before I block it all down tomorrow. Started to sand down the rest of the car, a process that is going to take the next couple of days. Body shop appointment is for next Saturday morning.

Some Pictures:



http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00682.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00684.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00685.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00686.jpg



....Oh i have also been scouring the local yards and when I saw a fresh A4 2.8L I rushed down to scavenge some parts:

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00687.jpg

Got a couple 2.8L heads with manifolds, two hours of my labor and $180 later.


Tomorrow's goal is to clean out the shop a little bit, then continue wet sanding and scuffing everything out...Followed by masking [headbang]

ZMEY
09-09-2012, 11:35 PM
wow Adam, thats amazing stuff, i didnt know you were so good at body work. good job

GO-GOTEKNO
09-10-2012, 12:20 AM
Im pretty Jelly , I wish I had the balls/knowledge to do my own bodywork.

TomyG
09-10-2012, 01:22 AM
yaaay laser being brought back to glory.

very good work [up]

ElliottG
09-11-2012, 10:47 AM
Nice. Do you mask the whole car off when primering your putty spots? I did that on my car and it's so freaking time consuming...

MadAudi
09-11-2012, 06:30 PM
Nice. Do you mask the whole car off when primering your putty spots? I did that on my car and it's so freaking time consuming...

The whole car is being painted anyway, so I wasn't masking the entire car just the part's nearest the priming area. I also had my gun set to a very narrow nozzle and low volume, not too messy.

Should finish up blocking tonight and send it to the body shop Saturday!

JDM EJ1 95
09-11-2012, 07:37 PM
Nice. Do you mask the whole car off when primering your putty spots? I did that on my car and it's so freaking time consuming...

you dont have to. primer is pretty easy to control with correct gun settings

hendrj5689
09-11-2012, 09:03 PM
Very nice! Wish I had the time and money for a project like this. Can't wait to see it after the body shop! Nice work! [hail]

ElliottG
09-11-2012, 09:58 PM
you dont have to. primer is pretty easy to control with correct gun settings

Yeah...but you still get a bunch of overspray everywhere...It's just getting primer on rubbers, etc sucks...

When I said mask off the whole car I was mistaken...I meant masking off the areas you did...

When I painted my hood I didn't even mask off the areas...just shot them cause the whole thing was being painted, like you are.

MadAudi
09-11-2012, 10:35 PM
Well I finished blocking down the car today and de-greased/ scuffed the whole thing. Didn't have to scuff it down as that's included in my body shop deal, but it gives me good peace of mind knowing that I gave it a once over.

Here are some pics of the car ready to be sent away:

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00688.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00689.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00690.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00691.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00692.jpg


Tomorrow I'm going to wash it all down and de-grease it completely (again, don't have to do it but I'll feel better after I do). The shop is a complete mess after all the body work, so it needs to be scrubbed down, organized, and prepped to start suspension work.

Body shop appointment is for 8:30am on Saturday morning. I'm going to have them sand it all down again, make sure everything is strait and even, remove trim, shoot it with base and clear, then color sand and buff it out. Should be back in the garage in a couple weeks for it's motor pull and then major suspension overhaul. Parts such as down pipes, turbo's, clutch, stock front brakes, suspension, and anything else I don't need will be for sale very soon!

ElliottG
09-12-2012, 05:29 AM
Nice. Can't wait to see the results. How much are they charging to spray it?

And what's the repair you did on the front fender? I didn't catch it reading before...

DiscoPotato
09-12-2012, 07:34 AM
I like.

MadAudi
09-12-2012, 08:19 AM
Nice. Can't wait to see the results. How much are they charging to spray it?

And what's the repair you did on the front fender? I didn't catch it reading before...

I rolled them tight to fit some bigger tires under there. So I primed and sealed it so it town have rust issues.

JDM EJ1 95
09-12-2012, 12:38 PM
Pull motor before.. paint engine bay

wildcat333
09-12-2012, 01:16 PM
I somehow stumbled upon this thread. Very nice prep I bet it'll be real nice after paint.


Sent from my iPhone using Tapatalk.

MadAudi
09-12-2012, 01:22 PM
Engine bay is so tight no one will see it IMHO.

Thanks guys, hopefully I'll update soon after paint!

Dutchsider
09-12-2012, 01:54 PM
Engine bay is so tight no one will see it IMHO.

Thanks guys, hopefully I'll update soon after paint!

I agree. My bay was filthy when I pulled my motor. Cleaned it down really good, but the results aren't really noticeable anyway.

Looking forward to pics of paint [up]

studlee
09-12-2012, 02:11 PM
great work...this should be fun....what is your total budget?...just asking because i would like to do something like this in the future.

MadAudi
09-12-2012, 03:47 PM
great work...this should be fun....what is your total budget?...just asking because i would like to do something like this in the future.

Without the interior, I am roughly at $20k right now budget wise....will end up around $25K though, I know it.

ElliottG
09-12-2012, 09:33 PM
How much is the body shop charging to spray the car? Nice work.

MadAudi
09-12-2012, 10:30 PM
How much is the body shop charging to spray the car? Nice work.

$1,700. My buddy works there so I am basically paying for materials. I rebuilt the engine in his Supra over the summer and this is him holding up his end of the deal.

tambat
09-12-2012, 11:13 PM
great work man! you've done a lot of work since i saw it on saturday. can't wait to see this beast finished come spring time

hendrj5689
09-13-2012, 10:03 AM
Looks awesome! What color are you having it sprayed? Can't wait to see it back from paint.

FLIPFLOPS4
09-13-2012, 12:34 PM
Prep work looks amazing, this is why I need to buy a house in the near future so I can work on my car in any way shape or form. Can't wait to see the results. Now if you don't mind me asking that 25k budget can't all be for body work lol, how are you dividing the budget?

MadAudi
09-13-2012, 01:53 PM
Prep work looks amazing, this is why I need to buy a house in the near future so I can work on my car in any way shape or form. Can't wait to see the results. Now if you don't mind me asking that 25k budget can't all be for body work lol, how are you dividing the budget?

Roughly 25K TOTAL. That's Body, Complete suspension/brakes, Engine, and Interior. Roughly $5K in the suspension/brakes, $13K in the engine, $2K in body work, and $2K in interior, but with all the hidden costs I expect around $25K.

2380S4
09-13-2012, 05:39 PM
but with all the hidden costs I expect around $25K.

Yep expect at least that. It's crazy how all the little things ad up quickly when your doing a build.

JDM EJ1 95
09-13-2012, 05:42 PM
Roughly 25K TOTAL. That's Body, Complete suspension/brakes, Engine, and Interior. Roughly $5K in the suspension/brakes, $13K in the engine, $2K in body work, and $2K in interior, but with all the hidden costs I expect around $25K.


you best be doing a full fuel system and a 3.0L for that price :P

MadAudi
09-13-2012, 05:45 PM
you best be doing a full fuel system and a 3.0L for that price :P

Pretty much it, idk if I want to stroke to 3.0L given how much boost I want to run, but definitively a fully built motor.

AudiTechS4
09-13-2012, 10:59 PM
First coat of mud.

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00644.jpg



What is the name of the product used here

MadAudi
09-14-2012, 06:34 AM
3M Lightweight filler with flex additive.

FLIPFLOPS4
09-14-2012, 07:14 AM
Roughly 25K TOTAL. That's Body, Complete suspension/brakes, Engine, and Interior. Roughly $5K in the suspension/brakes, $13K in the engine, $2K in body work, and $2K in interior, but with all the hidden costs I expect around $25K.

I gotcha, quite an investment but should be well worth all the time and money once it's complete, can't wait to see it completed.

MadAudi
09-15-2012, 11:07 AM
Dropped the car off at the body shop today....should have it back in a week or two.

So today is shop day. Cleaning out the gutters to stop my rain problem, re-organizing and cleaning everything, wiping down the floors, getting ready to reassemble most of the body and pull the motor.

Jesse S.
09-15-2012, 11:55 AM
Can I send my car to you, I need you to widebody it for me. [:D]

MadAudi
09-15-2012, 11:16 PM
Can I send my car to you, I need you to widebody it for me. [:D]

Funny you say that. I had a couple PM's and phone calls about doing a widebody on S4's (and building some engines). I am NOT a body guy, but with time and patience anything can be done.

Hopefully I'll have my car back next week so I can wet-sand, buff, and detail the exterior prior to tearing into the rest of it.

NeedingAnAudi
09-16-2012, 06:06 PM
^^ Funny you say you aren't a body guy.


Went over to MadAudi's today so he could plastic weld up my euro bumper. Sad that I just missed out seeing the S all prepped for bodywork. Thanks again Adam!

MadAudi
09-16-2012, 08:59 PM
^^ Funny you say you aren't a body guy.


Went over to MadAudi's today so he could plastic weld up my euro bumper. Sad that I just missed out seeing the S all prepped for bodywork. Thanks again Adam!

This does NOT mean I am now doing bodywork.[headbang]

Ha, no problem dude! I hope the car makes it safe and sound!

With that being said...project might be set back a couple weeks...I believe I am ordering Max Jax tomorrow...

Edit: Scratch that. Garage floor is too thin to safely support them. Tearing it apart next week.

Dutchsider
09-16-2012, 10:31 PM
This does NOT mean I am now doing bodywork.[headbang]

Ha, no problem dude! I hope the car makes it safe and sound!

With that being said...project might be set back a couple weeks...I believe I am ordering Max Jax tomorrow...

Ha ha ha ha, trying to avoid your PM inbox being blown up :D

MadAudi
09-21-2012, 11:22 PM
Got the call that Red Arrow is ready to be picked up from the body shop. Picking it up tomorrow morning, and spending the day wet sanding and buffing it all out.

Currently working with Max@034 on a suspension component order to be shipped next week... Will keep this thread updated!

MadAudi
09-22-2012, 10:38 AM
Here are some post body shop pictures. Car got a little dirty getting home but you get the idea. I will spend the rest of the day getting it assembled and buffed out, then put it up on the stands and start tearing everything out.

Pics:

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00694_zpsbf857969.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00696_zps68bd2e24.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00697_zpsfd969609.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00700_zps3739fa92.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00702_zps06c2512c.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00703_zps57ecf82b.jpg

Time to wrench![wrench]

s2the4
09-22-2012, 10:43 AM
Looks mint Adam your hard work paid off and the paint guy did a pretty good job from the pictures! Get this thing stripped!

Sour
09-22-2012, 12:52 PM
very nice congrats

hendrj5689
09-22-2012, 07:29 PM
Wow! Looks GREAT! Get to the wrenchin [wrench] Can't wait to see what the following updates have

MadAudi
09-22-2012, 10:30 PM
Pulled the engine today. Whoever worked on the car before was a poor mechanic as I found many bolts loose/ in backwards, and 3 were missing from the transmission to engine.

Pics:

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/IMG_0024_zpse50da6e4.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/IMG_0026_zpsf821ccd7.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/IMG_0027_zps83dc153f.jpg

Tomorrow It's going to be clean up around the shop, separate the trans from the engine, pull the parts I want to sell.

K04's and inlets will be available

APR Down Pipes will be available

Clutch assembly (not sure what it is yet) will be available as well.

Who wants it all?

nefkntym
09-22-2012, 10:59 PM
Great work! Repainted Laser Red looks amazing.

Subscribed.

S4 00 2.7
09-22-2012, 11:00 PM
Car looks great. Nothing like the gratification of doing that work yourself. Wish I had the patience to to body work.

PhatFree
09-23-2012, 01:00 AM
looks great! Wish i had the time and money to do work like this!

Subscribed!

thedudesA4
09-23-2012, 06:51 AM
Adam looks great dibs on the clutch

MadAudi
09-23-2012, 08:16 PM
Did some more work today. Removed the trans from the engine, mounted the engine to the stand. Pulled the turbo's and clutch.

I am crazy about keeping a clean work area, so after that I swept up, put all the tools BACK IN the tool box, and mopped up my floors. Pics of the progress:

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00705_zps5abd56a9.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00706_zpsfff7b219.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00707_zps968d7fc4.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00708_zps08dbb628.jpg


Now the RS4 clutch is already sold to a local guy. However, These are still available:

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00713_zps98c40d0c.jpg

APR Down pipes. $250 + Shipping (Mid-Pipe is also available for another $150 plus shipping)

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00715_zps964aaa0a.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00717_zpsd3f721e6.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00719_zpsa2234700.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00720_zps6c3a054b.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00721_zpsef9fd6fc.jpg

OEM K04 Turbo's with OEM RS4 Intake pipes. Turbo's have 40K on them, the usual minimal shaft play, but zero contact to the housing. Ran great for the 5K miles I put on the car before I pulled them, zero smoke, no whining, charge pipes were clean (no gobs of oil). One of the turbines looks like it has a nick on the impeller, I tried to catch it in the pictures. Originally wanted to keep them until I found out 034 made a single turbo kit.

$1250 plus shipping for the entire set-up.

Anything else for the twin turbo set-up is also for sale as well as HP2 front calipers and one steel upright, OEM sport shocks and springs, OEM rear sway bar. Exhaust manifolds are for sale, Y-Pipe, OEM intake manifold, etc.... PM me if you guys want anything! Keep this project funded!

NeedingAnAudi
09-24-2012, 07:16 PM
Hey Adam did your paint guy pull the door handles and lower mouldings when he sprayed?

MadAudi
09-24-2012, 08:46 PM
Hey Adam did your paint guy pull the door handles and lower mouldings when he sprayed?

I don't think so.

JDM EJ1 95
09-24-2012, 09:11 PM
I don't think so.

i hope he did.. if not. that paint will peel right at the edge of the moldings in no time.

MadAudi
09-24-2012, 09:14 PM
i hope he did.. if not. that paint will peel right at the edge of the moldings in no time.

just called him, he said he pulled EVERYTHING, so I should be good to go. However if he didn't.....

....good excuse to go wide body. [evilsmile]

FLIPFLOPS4
09-25-2012, 07:18 AM
Looking good, keep up the good work

hendrj5689
09-25-2012, 03:17 PM
....good excuse to go wide body. [evilsmile]

this^^[drool]

In all seriousness though, LOOKS AWESOME!

TimingBeltGuy
09-25-2012, 09:10 PM
Dude not bad for 20 days worth, you've done as much work that takes some ppl almost a year...what kind of turbo are you using for the single setup? Power goals?

Sales@J-Fonz
09-25-2012, 09:31 PM
This thread is full if win.

aysix
09-25-2012, 09:36 PM
This thread is full if win.

You are right. Normally people don't like to see things go well on here.

robsilvr85
09-26-2012, 09:06 AM
Great progress Adam. Looks good!

MadAudi
09-27-2012, 10:29 AM
I'll have another update tonight...sub-frames out and all. Someone buy my stuff so I can keep pushing forward!

FLIPFLOPS4
09-27-2012, 12:32 PM
I'll have another update tonight...sub-frames out and all. Someone buy my stuff so I can keep pushing forward!

Well what all do you have left that you haven't sold already?

MadAudi
09-27-2012, 12:41 PM
Well what all do you have left that you haven't sold already?

Y-Pipe

HP2 Calipers

K04 Turbo's and Inlets

Down Pipes

Stock Inter coolers

Anyone? Anyone?

Otherwise I'll eBay everything Saturday.

haggard69er
09-27-2012, 12:46 PM
Have you listed on vortex already?

MadAudi
09-27-2012, 01:00 PM
Have you listed on vortex already?

I refuse to go on Vortex.

juntsky
09-27-2012, 01:14 PM
lol well suck it up and list stuff over there. maximize your market man

FLIPFLOPS4
09-27-2012, 01:25 PM
PM me prices for the DP's and the Y-pipe

MadAudi
09-27-2012, 02:01 PM
PM's sent

haggard69er
09-27-2012, 03:58 PM
I refuse to go on Vortex.

I have found that stock parts sell quickly over there lol.

tekazgtr1984
09-27-2012, 09:52 PM
This thread is full if win.

+1. Awesome restoration thread. Laser red B5 FTW!

MadAudi
09-27-2012, 11:30 PM
Did some more work...

Tore out the suspension and sub frames. Going to strip everything down this week and clean up the underside of the shell, throw out what I'm not using, and ebay everything I have Saturday night to get some more funds rolling in here!

Some Pics:

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00727.jpg

The Hovering shell

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00726.jpg

No engine, no nothing!

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00725.jpg

Drivetrain...

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00723.jpg

More Drivetrain....

Hopefully I can start getting the frames coated and into the car this week, just waiting on parts from Max@034!!

FLIPFLOPS4
09-28-2012, 07:06 AM
Man, that body looks so fresh

MadAudi
09-29-2012, 09:27 PM
Did some more work today. Took apart all the suspension components, and sorted what is staying and what its going on the car. Going to pressure wash most of it down tomorrow, then start removing all the bushings/bearings, sand blasting, and painting all the components.

Pics:

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00728.jpg

The parts that are not going to make it back onto the car.

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00730.jpg

Parts ready to be cleaned and refurbished.

hendrj5689
09-30-2012, 12:28 AM
Looks like you'll have a lot of parts to put up for sale! Hopefully someone will find some use out of them!

MadAudi
09-30-2012, 09:05 PM
Did the shittiest job of the entire build today.

Washed down most of the parts, and then proceeded to pound, burn or cut out all the bushings/bearings/ other crap out of all the suspension parts in order to prep the for media blasting and painting.

Here is the result of an entire day of work (read: swearing and beer).

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00749.jpg

Started to sand blast some of the parts, here is a quick before and after of the rear upper control arm's.

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00748.jpg

Will spend the next couple of days sand blasting, welding up the sub-frames, and painting. Hopefully my suspension goodies get here soon!

MadAudi
10-04-2012, 10:30 PM
Quick update:

Got most of the parts sand blasted, cleaned up, and sealed. Going to do the sub frames and sway bar this weekend. Hopefully 034 sends out my parts ASAP so I can get the suspension back under this car and start tearing down the motor.

Only one pic this time:

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/IMG_0034.jpg


Edit:

All K04 parts have been sold and paid for, so its game on!

Dutchsider
10-04-2012, 10:45 PM
dammit! This makes me seriously miss the access to a glass beading booth that I used to have at my old garage. Nice work, quite jealous.

Cobra Commander
10-05-2012, 03:49 AM
Well done, this car might be the 'newest' driving b5 s4 since the 2002s were available for purchase

MadAudi
10-05-2012, 08:50 PM
Off topic question:

How do I get this build thread moved into the correct forum?

2380S4
10-05-2012, 10:15 PM
You posted a link in the build sticky, they should have moved it already. You might want to send a pm to the mod for this section so they can move it.

By the way love the progress, got me wanting to wrap my build up soon. Although I just brought home a new DD today, so that should help with moving things along.

JDM EJ1 95
10-06-2012, 10:27 AM
adam.. you want my gt28rs kit? 2500 bucks friend discount. ill take you for a ride with it in the car.

MadAudi
10-06-2012, 05:45 PM
adam.. you want my gt28rs kit? 2500 bucks friend discount. ill take you for a ride with it in the car.

That's a steal, but I think I am going to stick with the single turbo option here, for ease of future maintenance.

04/01-s4
10-06-2012, 08:36 PM
Talk about some serious motivation man keep it up. Making us all feel lazy. That's the way I like to do things though. If one thing breaks might as well replace everything else too. Mines been off the road for over a year now.

We seem to have the same taste in engine stands and floor jacks [wrench]

LINDW4LL
10-06-2012, 09:44 PM
Love the progress so far. Keep it up!

MadAudi
10-07-2012, 07:57 PM
Spent a good chunk of time working on the suspension prep this weekend. Finished sand blasting everything I was going to re-use. Sealed the frames, painted some more parts. Everything is ready for new bushings and install.

Everything waiting:

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00763.jpg


This week will be spent prepping the chassis and cleaning everything out, parts should be arriving any day now. Trying to get the suspension done by the end of the month, then I will start tearing down the motor and figuring out exactly what I want to do as far as the rebuild goes. Still staying single turbo though, without a doubt!

S4UCE
10-07-2012, 08:06 PM
This is awesome.

usmc.S4
10-07-2012, 09:10 PM
Wish I had the time and place to do this

Yesmar
10-07-2012, 09:13 PM
i envy , your time and disposable income. and organization of your workspace.

all my tools get piled on top of the bench, in order of last use. All the drawers are empty.

MadAudi
10-08-2012, 02:14 PM
i envy , your time and disposable income. and organization of your workspace.

all my tools get piled on top of the bench, in order of last use. All the drawers are empty.

After working in shops for a couple years, you learn to put everything back every night...otherwise it goes missing.

Thanks guys! Hopefully more updates soon!!

DiscoPotato
10-08-2012, 02:57 PM
So much win in here.

MadAudi
10-11-2012, 11:03 PM
Killed some time today. Tore down my axels, took the CV joints apart, blasted and cleaned, painted, and assembled as much as I could. One of the outer rear CV joints I had to order new as the ABS ring was damaged, and someone did a poor job of attempting to fix it.

Rear diff has been taken apart and re-sealed, waiting on fluid and axle seals for that. Just killing time until the rest of my parts get here.

Pic:

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00767.jpg


Tomorrow I will turn my attention to detailing and cleaning up the transmission, should have another pic by the end of the day. Parts are due here Tuesday/Wednesday, so It should be a roller by next weekend.

JDM EJ1 95
10-12-2012, 12:43 PM
where do you get this ambition?

MadAudi
10-12-2012, 12:47 PM
I enjoy building a proper car, tip to tail.

ggg20t
10-12-2012, 01:19 PM
this is definitely inspiring me to do the same. I just finished a complete restoration on a British car, and i've been quite lazy. Love your work - properly done, with no corners cut! Cannot wait to see the engine build.

AudiSportB5S4
10-12-2012, 01:26 PM
Next year I had planned on doing a refresh to my engine, new turbos, and some cleaning. You are taking that to another level, even though this is exactly what I want to do!! I'd love to have the skillset to tackle this kind of stuff myself.

[up] Look forward to hearing how it feels when it's all together, I'm sure it'll be great!

USMC1488
10-12-2012, 06:37 PM
Truly amazing, this is a complete restoration, your s4 is going to drive like new!

MadAudi
10-12-2012, 06:37 PM
Got bored again. So I drained and cleaned up the transmission, here's a couple of pics:

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00770.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00768.jpg


Wont have parts until Tuesday, so looks like I have a weekend away from the car....so I guess it's time to hunker down and start figuring out a parts list for my engine.

MadAudi
10-15-2012, 02:52 PM
Shiny new parts are arriving from 034 and ECS tomorrow...

But until then, anyone have an RS4 intake manifold they are willing to part with?

naudlee
10-15-2012, 03:19 PM
I enjoy building a proper car, tip to tail.

I appreciate your attention to detail... I feel its VERY MUCH NEEDED if you want a solid B5 S4, plain and simple. No other way to do it!

MadAudi
10-16-2012, 11:14 PM
Most of my suspesion parts came in today, I'm still waiting on some hardware, my rear sway bar, and rear CV boot kits, but here is the jist of it:

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00774.jpg


So I started to tinker away:


http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00777.jpg

Here is a freshly re-sealed and re-filled diff.

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00778.jpg

Front knuckels ready to go with new bearings and all.

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00779.jpg

Rear knuckels with new bushings and bearings.

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00781.jpg

Rear coil overs ready with fresh bushings in the upper arms.

I should be rolling by next week, then its time to push it out of the garage, power wash it, and start prepping the engine. Some side work while I do the engine wont hurt either!!

juntsky
10-16-2012, 11:47 PM
i'm seriously impressed by the effort put into this. bravo man

Duds
10-17-2012, 09:23 AM
So am I, subscribed. [up]

DiscoPotato
10-17-2012, 11:14 AM
I love it.

FLIPFLOPS4
10-17-2012, 01:32 PM
Yeah, congrats man, definitely helps when you have the knowledge, tools and space to do most of the work. When your all done your pretty much going to have a brand new 11 year old car lol..... Your definitely gonna need to make it to WF19 or H2o next year so we can all see your work.

Tec_Nine
10-17-2012, 01:34 PM
Great work, love you attention to detail

un1ko
10-17-2012, 02:12 PM
Nice work Adam! Man, I wish I had that much space in my garage.... Lol

00SantorinS4
10-17-2012, 02:22 PM
So much win. So much envy!

MadAudi
10-17-2012, 09:06 PM
Didn't get much done today, tried to install the front sub frame but due to the PO stripping one of the bolts, I had to order a heli-coil kit to repair it. Installed the new front tie rod assemblies and boots. Tried to finishing rebuilding my axels only to find out ECS sent the wrong boots, so couldnt get that done either. Hopefully my kit will be here tomorrow so I can continue progress. So here is a pic of the bushings all pressed in and happy:

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00784.jpg


Deff a rough day, maybe tomorrow will be better?

Dutchsider
10-17-2012, 09:25 PM
Progress hindrances like that are serious demotivators [:(]

rage385
10-18-2012, 11:46 AM
Dude......that is amazing! Good Job

MadAudi
10-18-2012, 10:05 PM
Here's some more stuff making it's way back onto the car as of this morning:

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00787.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00790.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00791.jpg


Should have another bigger update over the weekend.

Anyone have a set of 18" wheels with crap tires I could borrow over the next couple months to roll the car around on?

lo-lyfe
10-19-2012, 08:50 AM
I love this thread. Just shows how you can bring your car back to near mint state with enough hard work. Inspiration for when I get to that point. Take it slow and do it right...

S4 00 2.7
10-19-2012, 04:00 PM
I gotta do all this sometime.

Meow
10-19-2012, 10:33 PM
Just read through the thread and all i gotta say is... AWESOME!


http://www.youtube.com/watch?v=oP3ezq7G5E8

I would love to do something like this to revive an s4...

MadAudi
10-20-2012, 05:12 PM
Made some more progress today.

Entire front end is done. Sub frame installed to factory torque specs with new hardware, New tie rods and boots, all new 034 Density control arms and hardware. New wheel bearings in the aluminum spindles, AP/034 BBK installed with stainless lines, ST coil overs installed. Everything was torqued down AT RIDE HEIGHT!

Some pics:

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00797.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00798.jpg

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00801.jpg


Rest of my parts should be here Tuesday, so car will be a roller by the end of next week. Plan is to roll it outside, power wash the engine bay, wash the entire car, and put a cover over it while the engine is being built. Need to get some side work done to keep the project funded!

USMC1488
10-21-2012, 09:07 AM
EPIC!

MadAudi
10-24-2012, 11:04 PM
Got the rest of my parts in this week so some work has been done! Axel's are now fully rebuilt, all the sub assemblies were completed Tuesday night.

The entire suspension is now put together and installed in the car. Wheels should be here tomorrow, so the car should be sitting on its new suspension by the weekend. It will be rolled outside, washed, and covered....then as soon as I pay down some of these suspension goodies, it's engine time!

Pics:

http://s14.postimage.org/sxha36rqp/IMG_0042.jpg

Axel's freshly assembled with new grease, boots, and gaskets.


http://s9.postimage.org/3uawvk21b/IMG_0041.jpg

All Parts prepped and ready for install!

http://s15.postimage.org/3uc5iy53f/IMG_0044.jpg

034 BBK installed along with the rest of the rear end.

http://s11.postimage.org/w0g96myab/IMG_0045.jpg

Crude picture of the entire rear end. 034/Nuespeed Sway bar, some billet goods, all braided brake lines, everything fresh and ready to go!.....BECAUSE RACECAR!!

thedudesA4
10-25-2012, 05:01 AM
Looks great bud

FLIPFLOPS4
10-25-2012, 07:02 AM
So fresh and so clean clean...... Keep up the good work

usmc.S4
10-25-2012, 07:27 AM
I want all this

S4 00 2.7
10-25-2012, 10:32 AM
Looking good.

hendrj5689
10-25-2012, 10:37 AM
Looks great! I'm sure it's going to feel amazing to have it rolling [:D]

Slümdawg
10-25-2012, 02:55 PM
Subscribed. What an inspiration, this is awesome to watch

mkemk3
10-25-2012, 04:10 PM
love this car

OMGHI
10-25-2012, 04:25 PM
love this man.

MadAudi
10-25-2012, 05:29 PM
Got delivery notice from UPS. Wheels are sitting in my garage while I sit at work looking at the clock....

Will post pic's tonight!

MadAudi
10-25-2012, 08:17 PM
Here are some more pics, got the wheels on and car on the ground finally. Took a couple better pics of suspension work. Pushing it outside tomorrow, washing it and covering it back up. Got some side work to do then starting on the engine!

http://s8.postimage.org/xbbnpgis5/DSC00803.jpg


http://s9.postimage.org/lxfh3hkb3/DSC00809.jpg

http://s18.postimage.org/9rrgslod5/DSC00811.jpg

NeedingAnAudi
10-26-2012, 11:12 AM
Nice choice Adam, should push it to the meet tomorrow

MadAudi
10-26-2012, 11:16 AM
I'll be there in my bro's B5 if it doesn't end up in the paint shop.

USMC1488
10-26-2012, 12:07 PM
It is a new B5. many people have the skills to do what you are doing, EXCEPT the time in which you have done it is amazing. It takes most people years to get to where you are now. You took the typical beat hard and put away wet B5 and turned it into a fully restored OEM+++++++++++++++++ car. In my opinion your investment is welll justified as you now have a new car. Nice job!

MadAudi
10-26-2012, 11:01 PM
Mailman brought a goodie today....

http://s11.postimage.org/q125dsbr7/IMG_0049.jpg


http://s18.postimage.org/9sy8i5pm1/IMG_0050.jpg


Car is outside, engine bay is pressure washed, everything is cleaned up! Must cater to some other B5's over the next few weeks, then digging into the engine.

Tec_Nine
10-27-2012, 09:58 AM
Good, Good

holywater
10-27-2012, 10:34 PM
Man, what a great thread and picture story...absolutely amazing how you did everything yourself except the paint job (how much did you lay down for the respray?)

Can you have me down as the first person to call when you decide to sell and move onto your next project when you get bored with it...LOL.

DrnknCamel
10-27-2012, 11:03 PM
Awesome work here! Kudos!

MadAudi
10-28-2012, 02:25 PM
Man, what a great thread and picture story...absolutely amazing how you did everything yourself except the paint job (how much did you lay down for the respray?)

Can you have me down as the first person to call when you decide to sell and move onto your next project when you get bored with it...LOL.

Lol, you are actually 3rd in line if I ever do sell it.

Thanks for the kind words everyone!

NeedingAnAudi
10-28-2012, 02:41 PM
Can I test fit those wheels? They look like they would fit my car really nicely.

Kruat
10-28-2012, 07:05 PM
This thread is an inspiration. This is how you build a B5 S4. Your work and attention to detail is impeccable. I hope once I move into my new house, with shop, I'll have the balls/time to attempt this on my car. Keep up the good work, can't wait to see the finished product. What are your plans on the interior?

hendrj5689
10-28-2012, 10:18 PM
Looks AMAZING! If I lived in the Chicago area, I know who I would call to work on my car! Can't wait to see moar!

Mr. KOOL AID
10-28-2012, 10:55 PM
It shows why you haven't been able to make it to some of the Saturday meets lately. Keep on [wrench]

Tiluleshpingen
10-29-2012, 10:45 AM
just went through all the 5 pages .. great thread great build man!

boss99er
11-13-2012, 12:17 PM
No updates fora while......I'm having withdrawals!

usmc.S4
11-13-2012, 01:02 PM
Nice wheel choice. I got black ones on my laser.

MadAudi
11-13-2012, 03:11 PM
Will update soon. Currently doing an Auto to Manual swap and Stage 3 build for a customer of mine, but will be back on this soon!

mjacksons4
11-15-2012, 12:51 AM
Looks great bud....hopefully this summer ill see it in person....and you can see the changes to my car

MLJS4
11-15-2012, 01:32 AM
Can't believe I've never seen this , damn nice work man

LightningLou
11-15-2012, 01:40 PM
Looks awesome man great job! Nice color too. [;)]

MadAudi
11-17-2012, 12:13 PM
Update:


Unfortunantly, this thread will not include a bunch of engine build pron...

I just secured a 3.0L fully built engine locally that will be going in....[evilsmile]

http://alexslover.files.wordpress.com/2010/03/jeremy-clarkson-more-power.jpg

ElliottG
11-17-2012, 12:34 PM
Did you ever have troubles getting an alignment for the car after you took the rear subframe out? I'm having major problems aligning the rear of my car and I believe I have to shift the subframe over. Did thy have to do that on your car as well?

Also one more thing: when you did the patch panels for the front bumper, did you use a flexible body filler or just regular stuff? Just wondering for my future purposes.

JDM EJ1 95
11-17-2012, 12:46 PM
Update:


Unfortunantly, this thread will not include a bunch of engine build pron...

I just secured a 3.0L fully built engine locally that will be going in....[evilsmile]

i got the process pictures if youd like to pretend

JDM EJ1 95
11-17-2012, 12:49 PM
time lapse

http://imageshack.us/a/img263/5174/headson.jpg

'00nogaros4
11-17-2012, 04:26 PM
If someone is knowledgeable about building a 3.0 I wouldn't mind chatting via pm. I am thinking about building one but I have not decided yet..

DetailersDomain
11-17-2012, 05:40 PM
that's awesome!

MadAudi
11-21-2012, 06:26 PM
As I am waiting on parts for a couple more cars I'm working on lets talk fueling for this project.

Motor will be a fully built 3.0L with RS4 intake

Will have an 034 STK with 6265 Turbo

The car is going to be a DD, so 93 fuel only!

I am thinking:

044 Pump in the tank

-10 Feed and Return lines

034 Fuel rails with -10 fittings

Aeromotive FPR with -10 Outlets

750CC EV 14 Injectors

Russel Pro-Filter Fuel Filter with -10 Outlets


Opinions? Comments? Overkill or not enough?

JDM EJ1 95
11-21-2012, 06:35 PM
youll need more than a single 044 in tank

use IE's dual surge setup.. with a aeromotive 340 in tank to feed.

UkuRiSh
11-21-2012, 06:56 PM
As I am waiting on parts for a couple more cars I'm working on lets talk fueling for this project.

Motor will be a fully built 3.0L with RS4 intake

Will have an 034 STK with 6265 Turbo

The car is going to be a DD, so 93 fuel only!

I am thinking:

044 Pump in the tank

-10 Feed and Return lines

034 Fuel rails with -10 fittings

Aeromotive FPR with -10 Outlets

750CC EV 14 Injectors

Russel Pro-Filter Fuel Filter with -10 Outlets


Opinions? Comments? Overkill or not enough?


Nice but why you pick the old 6265 ? get new one CEA 6266 i have one for sale .

Feed -8 AN and -6 AN retun is planty

1dopea4
11-21-2012, 07:19 PM
awesome!!

MadAudi
11-21-2012, 09:02 PM
Nice but why you pick the old 6265 ? get new one CEA 6266 i have one for sale .

Feed -8 AN and -6 AN retun is planty


What kind of inlet/outlet on the exhaust side? V-Bands?

Shoot me a PM, if it's a decent deal we can talk.

lorge1989
11-21-2012, 09:22 PM
This looks stunning. The attention to detail is really amazing, and please finish it! I don't mean that negatively, but a lot of people will get bore/un-interested/broke by the time they are in the middle. Your build does look different from any other I've seen though. Just make sure when it comes to the motor, take you time and do everything just right. Seeing that you do this for a living (?) that shouldn't be a problem. Motivation for saying that just comes from builds where I have read about people not doing things completely as they should, then wasting money trying to fix the issues they caused. More than once this cause the demise of the build as a whole, all when it could have be avoided if they were not being so dumb.

Also the wheel choice is spot on, I couldn't really thing of a more appropriate one for this build.

Also what are you doing to the tranny internally? You said it was rebuilt recently? Syncros, collars all new? If so that's f****** sweet!

Keep it up!

MadAudi
12-09-2012, 08:35 PM
Another time for an update, it's been a while.

Picked up a 3.0L fully built motor from Ricky (JDM EJ1 95) parting out:

http://s11.postimage.org/yl3jrqpw3/IMG_0119.jpg

http://s15.postimage.org/krhuzxua3/IMG_0120.jpg

http://s18.postimage.org/mpqex7ww9/IMG_0121.jpg

http://s9.postimage.org/hvsys91en/IMG_0122.jpg

And the spec's:

2.7T Block
3.0L Crankshaft
Vast performance rods and pistons(stroker setup, 82.5mm)
ARP rod bolts
Crank was checked/balanced to rev to 8500
Raceware main studs
Raceware head studs
2.8L big port heads, completely re-done.
Intake ports cleaned up
Valve bowls ported
2.8 cams
Supertech 1mm over intake valves
Supertech exhaust valves
Supertech/034 springs and retainers
RS4 intake manifold ported to match the heads and Hemi TB


Coming hopefully in the next week or so from 034:

Tilton Twin Disk Clutch w/ 034 Flywheel
034 Track density engine and trans mounts
JHM Solid Linkage shifter upgrade
Single Turbo manifold and Down Pipes
Tial MV-R 44mm waste gate
Precision 6266 Turbo

Then it's off the ceramic coating.


Should have the motor back in the chassis around the beginning of the year then it's time to start finishing things up.

JDM EJ1 95
12-09-2012, 08:38 PM
sexy engine :)

ps.. might as well do a quick re torque on those head studs just to be sure..

motor only has 1500 miles on it.. i did a re torque after a few heat cycles so it should be fine.. but it doesnt hurt to check.

haggard69er
12-09-2012, 09:12 PM
As I am waiting on parts for a couple more cars I'm working on lets talk fueling for this project.

Motor will be a fully built 3.0L with RS4 intake

Will have an 034 STK with 6265 Turbo

The car is going to be a DD, so 93 fuel only!

I am thinking:

044 Pump in the tank

-10 Feed and Return lines

034 Fuel rails with -10 fittings

Aeromotive FPR with -10 Outlets

750CC EV 14 Injectors

Russel Pro-Filter Fuel Filter with -10 Outlets


Opinions? Comments? Overkill or not enough?

Depends what your hp goal is. Go with a magnaflow 750 in tank, 10an feed, 8an return, you will never have to upgrade. This is the setup i will be running on my car because there is no need for multiple pumps or a surge tank, keeps it simple and highly affordable.

nefkntym
12-09-2012, 10:13 PM
Depends what your hp goal is. Go with a magnaflow 750 in tank, 10an feed, 8an return, you will never have to upgrade. This is the setup i will be running on my car because there is no need for multiple pumps or a surge tank, keeps it simple and highly affordable.

I am running a -10 feed and a -8 return, IE fuel rails with a aeromotive regulator and filter, only difference is that I am using a Weldon pump. Basically my thoughts were the same, I never wanted to upgrade again.

haggard69er
12-10-2012, 01:00 AM
I am running a -10 feed and a -8 return, IE fuel rails with a aeromotive regulator and filter, only difference is that I am using a Weldon pump. Basically my thoughts were the same, I never wanted to upgrade again.
Plus it is way cheaper :) How is the noise on your weldon?

Boarder
12-21-2012, 10:05 PM
What type if sander are you using in this picture. Where can i pick one up?

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00665.jpg




Sent from my DROID RAZR using Tapatalk 2

DiscoPotato
12-22-2012, 06:58 AM
OK you just kicked shit up a notch.

Boarder
12-22-2012, 11:19 AM
OK you just kicked shit up a notch.

How so

Sent from my DROID RAZR using Tapatalk 2

JDM EJ1 95
12-22-2012, 01:47 PM
How so

Sent from my DROID RAZR using Tapatalk 2

im guessing the 3.0L longblock was the kicker

MadAudi
12-23-2012, 02:11 AM
What type if sander are you using in this picture. Where can i pick one up?

http://i21.photobucket.com/albums/b254/polskikolarz/Project%20Red%20Arrow/DSC00665.jpg

Sent from my DROID RAZR using Tapatalk 2



It's just a harbor freight orbital sander with pad, you can get em for like $40. Home depot has all the attachments for it as it uses a standard 5" disk.

My STK kit will be shipping the first week of January, then it's off to ceramic coating and hopefully plopping the engine back into the car....then it's just a matter of putting it all back together piece by piece.

MadAudi
12-26-2012, 06:22 PM
Another quick update:

The first component of my next batch order came in:


http://s13.postimage.org/f8bscdqzr/IMG_0179.jpg


JHM shifter kit. I already have the shfiter just needed the other two parts of the trio!! STK should be here in a little over a week...then time to drop it back in!

MadAudi
12-30-2012, 06:05 PM
Another little update:

A buddy of mine went junkyard hunting and found one of these:

http://sphotos-a.xx.fbcdn.net/hphotos-ash4/307146_10151594483563272_1064874972_n.jpg

That he instantly called me about and allowed me to purchase...so euro trunk here I come!!


More updates soon!

DiscoPotato
12-30-2012, 07:57 PM
im guessing the 3.0L longblock was the kicker

Ding ding ding

Brodyaga
01-08-2013, 12:07 AM
just when I get to thinking that my build is awesome... lol

MadAudi
01-09-2013, 10:39 PM
Well.....looks like my STK stuff from 034 shipped out so I'll update Saturday/Sunday with more pics of the goodies.

For the time being, I had another change of heart about the exterior...anyone want to buy a Complete S4 Bumper?!

JDM EJ1 95
01-10-2013, 08:13 AM
I'll trade you those 2.8 heads for the bumper If you paint it nogaro

hallvardr
01-10-2013, 05:36 PM
http://s15.postimage.org/3uc5iy53f/IMG_0044.jpg

Are these the Lucas 43 calipers?
Did you change the gaskets and pistons on them, or just paint?

MadAudi
01-11-2013, 05:16 PM
I'll trade you those 2.8 heads for the bumper If you paint it nogaro

Ill trade my OEM bumper for your Rs4 style bumper.


they are rebuilt lucas calipers.

Gadget
01-12-2013, 02:43 AM
Amazing build bro. Subscribed and waiting for more. Beautiful car !!!

MadAudi
01-13-2013, 09:56 PM
So the Fedex man dropped this off on Saturday:

http://sphotos-a.xx.fbcdn.net/hphotos-snc6/263262_10151624123323272_491944704_n.jpg

I hopefully should be able to get back to work on it this weekend...woot!

LINDW4LL
01-13-2013, 10:17 PM
This thing is going to haul major ass!

kbjy11
01-13-2013, 11:00 PM
best build thread i've seen in a while.

Keep the updates coming!

Gadget
01-13-2013, 11:09 PM
I would love to see this in person ... What a great build !!! Waiting for more !!

Hyphy
01-13-2013, 11:53 PM
damn man....this is amazing.

Tyler S4
01-13-2013, 11:57 PM
such and inspiration lol

Monty23
01-14-2013, 06:46 AM
sexy clutch!

hallvardr
01-18-2013, 05:56 PM
they are rebuilt lucas calipers.[/QUOTE]

where did you get the rebuild kit?

MadAudi
01-18-2013, 06:32 PM
A local parts store here that specializes in euro parts.

However, Audi did offer an OEM rebuild kit so I;m sure ECS or someone has it.

MadAudi
01-24-2013, 10:40 PM
http://sphotos-b.xx.fbcdn.net/hphotos-prn1/c67.0.403.403/p403x403/58215_10151646762288272_939012372_n.jpg


Just playing around in the garage. More updates next weekend!

MLJS4
01-24-2013, 11:01 PM
http://sphotos-b.xx.fbcdn.net/hphotos-prn1/c67.0.403.403/p403x403/58215_10151646762288272_939012372_n.jpg


Just playing around in the garage. More updates next weekend!


nice i always wanted to do white valve covers since my ypipe is white

MadAudi
02-03-2013, 11:26 AM
Quick, non exciting update:


Picked up some seat's for the S4...the White/Black Alcantara ones will be for sale when they get pulled next weekend. Probably gonna ask $250 for the set if anyone is interested....


http://sphotos-b.xx.fbcdn.net/hphotos-snc6/285197_10151694135443272_1786089062_n.jpg

http://sphotos-b.xx.fbcdn.net/hphotos-ash3/486788_10151694135438272_1626230415_n.jpg


With that being said, motor will be going in shortly, shooting for a running car by the end of the month!!

Yesmar
02-03-2013, 01:09 PM
nice, red with white int. is a gorgeous contrast.

Tony T
02-05-2013, 07:36 PM
the White/Black Alcantara ones will be for sale when they get pulled next weekend. Probably gonna ask $250 for the set if anyone is interested....

I might be interested.

MadAudi
02-06-2013, 06:04 PM
http://sphotos-a.xx.fbcdn.net/hphotos-prn1/44353_10151702033043272_297140550_n.jpg


....well then guess I gotta start working on it again.

hendrj5689
02-07-2013, 08:45 AM
http://sphotos-a.xx.fbcdn.net/hphotos-prn1/44353_10151702033043272_297140550_n.jpg


....well then guess I gotta start working on it again.

[wrench] can't wait to see it running! You were thinking by the end of the month correct?

TXb5s4
02-07-2013, 01:53 PM
http://sphotos-a.xx.fbcdn.net/hphotos-prn1/44353_10151702033043272_297140550_n.jpg


....well then guess I gotta start working on it again.

What wheels BBS RK?
size
offset
no spacers required?

I want to get rid of my spacers.

Fourplay
02-07-2013, 02:32 PM
Quick, non exciting update:


Picked up some seat's for the S4...the White/Black Alcantara ones will be for sale when they get pulled next weekend. Probably gonna ask $250 for the set if anyone is interested....



Very interested, let me know what you end up deciding.

On topic, the car looks fantastic, can't wait to see this thing finished, it's going to be incredible.

HelthInsXpert
02-07-2013, 03:00 PM
This build looks amazing. You have some real skill.

helli217
02-07-2013, 05:41 PM
What is your process for restoring the suspension/chassis parts? Obviously pull, remove bearing/bushings/etc, blast clean, then what? What process, paints, chemicals? Im going to be doing a similar restore to mine, and Iwill be doing all of the work except some of the body/paint myself. I just don't know how to prep/paint these parts so they will last. Thanks.

AWESOME BUILD.

MadAudi
02-08-2013, 06:56 PM
http://chicago.craigslist.org/wcl/cto/3604155432.html


Someone buy my 90 to keep this S4 funded plz!!


Alcantara is SOLD locally.

MadAudi
02-09-2013, 12:34 PM
http://sphotos-b.xx.fbcdn.net/hphotos-ash3/579591_10151708511703272_189810251_n.jpg

because aint no one like OEM fuel lines and EVAP systems.

...the work continues.

MadAudi
02-10-2013, 09:11 PM
http://sphotos-b.xx.fbcdn.net/hphotos-prn1/604005_10151711862378272_210829103_n.jpg


Redid the headliner today, gonna do the sound system tomorrow and run the wiring for my dual surge set-up before I put the interior back together. More pic's to follow before the mechanical goodness comes in.

sherbet
02-10-2013, 09:59 PM
honestly this is one of the best threads ever. Good work man, you really are an enormous inspiration. [up]

1999blacka4
02-11-2013, 01:52 PM
Great work man. I really shouldn't be the one to give you input, but have you ever thought of gunmetal rims on that thing?

Alaga
02-11-2013, 05:40 PM
Are you going to be selling your trunk lid? I need a Laser red on on my S4 Mine had started to rust and chip paint around the plate and its gotten very bad and I wanna get it taken care of!

MadAudi
02-11-2013, 09:47 PM
Yes my US trunk lid will be for sale, but it is freshly painted and I need to remove it's locking mech to put in my new one. PM me if your serious, it MUST be picked up.

MadAudi
02-12-2013, 08:11 PM
Did some more work today:

http://sphotos-a.xx.fbcdn.net/hphotos-ash3/644010_10151716180263272_1861980549_n.jpg

http://sphotos-b.xx.fbcdn.net/hphotos-ash3/17660_10151716180803272_2058732553_n.jpg

http://sphotos-b.xx.fbcdn.net/hphotos-ash3/560099_10151716181468272_1954340312_n.jpg

http://sphotos-a.xx.fbcdn.net/hphotos-snc7/582754_10151716181958272_551772138_n.jpg

http://sphotos-a.xx.fbcdn.net/hphotos-snc6/285607_10151716182328272_194317972_n.jpg

http://sphotos-b.xx.fbcdn.net/hphotos-ash4/379330_10151716182818272_1645459051_n.jpg

Speakers are in and interior is getting slowly reassembled...


http://sphotos-b.xx.fbcdn.net/hphotos-snc7/5838_10151716185248272_1203008446_n.jpg

Surge pump wiring ran and relay installed.

More updates tomorrow....

MadAudi
02-14-2013, 07:55 PM
Not much progress today. Tightened up my side skirts to the body more, and undercoated the car while there were no lines or anything under it. Ordering another huge round of parts this weekend...

Yesmar
02-15-2013, 04:52 PM
excellent resto your doing. I love it.

MadAudi
02-19-2013, 07:54 PM
Made some more progress over the past two days.

Fuel lines for the surge pumps/tank are run.

Seats are in along with the airbag module and tested, no codes!!

Aluminum radiator is in the core and electric fan is installed and wired up.

Going to start heat wrapping stuff tomorrow, hopefully motor is in this weekend!

pics:

http://sphotos-a.xx.fbcdn.net/hphotos-ash4/307439_10151731348458272_111389802_n.jpg

http://sphotos-b.xx.fbcdn.net/hphotos-prn1/18292_10151731347933272_1441135147_n.jpg


http://sphotos-b.xx.fbcdn.net/hphotos-ash3/545797_10151731347013272_1984753388_n.jpg

http://sphotos-a.xx.fbcdn.net/hphotos-prn1/482483_10151731347498272_1652398282_n.jpg

konradwax
02-19-2013, 08:23 PM
Lots of work, good job!

JDM EJ1 95
02-19-2013, 10:00 PM
them seats look rough compared to the rest of the car.

good progress tho!

Jesse S.
02-19-2013, 10:08 PM
Great work man. I really shouldn't be the one to give you input, but have you ever thought of gunmetal rims on that thing?

Dont do it, it looks tacky as hell. [rolleyes]

MadAudi
02-19-2013, 10:10 PM
Dont do it, it looks tacky as hell. [rolleyes]

I agree with this.

I've always wanted these BBS's and now that I can afford them, I got em!

The seats look awful in pictures, they aren't even cleaned up properly yet!

More to come tomorrow....

MadAudi
02-21-2013, 08:14 PM
Got some more parts today so progress has been made:

2.8L Freeze plugs installed

http://sphotos-b.xx.fbcdn.net/hphotos-snc6/226894_10151735290658272_2136662069_n.jpg


2.8L Manifolds installed:

http://sphotos-a.xx.fbcdn.net/hphotos-prn1/548621_10151735290908272_378097941_n.jpg

OEM 2.8L Heat Shields used!!!

http://sphotos-b.xx.fbcdn.net/hphotos-ash3/548671_10151735291628272_996799344_n.jpg

Engine Assembly:

http://sphotos-a.xx.fbcdn.net/hphotos-ash3/549325_10151735291858272_1305779078_n.jpg

Up-Pipe installed and heat wrapped:

http://sphotos-a.xx.fbcdn.net/hphotos-prn1/521530_10151735292143272_149505953_n.jpg

Some test fitting:

http://sphotos-a.xx.fbcdn.net/hphotos-ash4/487246_10151735292408272_755016932_n.jpg



Might even toss it into the car tomorrow....more to come!!