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#Avantbuild
05-09-2014, 09:57 PM
*********BEWARE - PHOTO HEAVY***********


Hello Audizine,

First post here, and not planning on being the last. I'm excited to share with you what I've been dreaming of for over a year. Let me give you a little background before we jump into the build thread.

I'm a 23 year old full-time student at Walla Walla University studying Automotive Management which is a 4-year B.S. Degree. My first car was a 2000 VW GTI 2.0l 8V. I loved that car. It didn't stay stock for long, as I added an R32 bodykit, meganracing exhaust, R32 replica wheels, and a few other things. I eventually built my own custom turbo kit and brought the dog of a 95whp 2.0l to 175whp with the help of a C2 chip from DJM in Portland, OR. Ever since then I've been excited about cars, speed, society, the euro family, etc. In 2009 I sold my gti and bought a Mk4 R32 with 72,000 on the OD. I miss that car every day, I had so much fun with it. It stayed stock for awhile, but I eventually added Koni coils, Keskin KT-1 staggered wheels, HID HL, Double Din HU, Custom exhaust, and a few other things.

In 2011-2012 I attended Hallmark Institute of Photographer, in Massachusetts, where I trained in their rigorous program to be a "Professional" photographer. I don't think you can technically call yourself a professional unless you're living off the income you're getting from that venture, so I wouldn't say I am a professional... but more of a very experienced amateur. Anyways, I discovered after returning from the East Coast (I bought a 2000 Audi S4 in Maine and drove that while I was over there - loved it) I found out my R32 just wasn't practical in my business. I have super heavy equipment that I carry around all the time, long light stands, backdrops, etc. The trunk in the R32 didn't even fit my guitar, so the gear necessary for a full production photo shoot didn't even have a chance. It also was expensive to maintain, and not kind to my wallet for fuel or insurance. So, I parted with my beloved .:R and, in my opinion, stepped up the game a bit, and bought myself a 2006 A4 Avant, 6-speed, Quattro, non-sline.

I bought the Avant with 97,000 miles on it from a doctors family up in Seattle where it has been serviced at Barrier since it rolled off the truck when the original owners bought it. You couldn't find a cleaner car with 100k on it. So, naturally, when I bought it I promised the previous owners while signing the title that I would take care of it and make them proud. Hehehehe, little did they know I had big plans for their beloved wagon....

I'm graduating college on June 15th, 2014, and part of the automotive program is to have a senior project, where we demonstrate to our department some of the skills we've learned in the last four years. I decided to go a little beyond the requirements and do a full suspension build.

So, here we are. This is my build thread. Lets get into the good stuff. [up]

Check out my instagram hashtag to follow my build! #Avantbuild
OR, follow me @kurtislamberton

THE PLAN....

I wanted to have a stanced wagon, but hated not being able to get into driveways with my R32, so I decided to do air ride. Accuair is the name of the game, so after talking with them at SEMA in 2012 and 2013 I decided they were my top choice. I didn't want to sacrifice the trunk for the air ride components, because that would defeat the purpose of buying a car with a bigger trunk for all my photo gear... so, later on in the build I'll show you what I came up with.
I'll try to explain some of the process with pictures, but I won't go into extreme details as to torque specs of bolts.. or what mm that bolt was etc. If anyone has questions please PM me and I'd be more than happy to share what I know. I've made a lot of mistakes and learned a lot of lessons, so I'd love to help you NOT repeat those. lol

List:
Accuair B8 Sport Kit - retrofit
B8 A4 S-Line Front bumper retrofit
RNS-E install
RS6 MFSW with paddles
MRR GF6 wheels
Custom trunk for components


Here's my A4 Avant the day I picked her up.
http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Start/Avantbuild_Start-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Start/Avantbuild_Start-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Start/Avantbuild_Start-3.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Start/Avantbuild_Start-3.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Start/Avantbuild_Start-4.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Start/Avantbuild_Start-4.jpg.html)


I started planning my build back in September of 2013, and by November I started ordering parts. I didn't start the build until January of 2014. I talked to Accuair at SEMA last November and bugged them about my build idea, and I entertained Derek about an idea I had about making the E-Level ride heights change with the paddle shifters. He told me that at this point they've never seen it done and weren't sure it was possible, so I decided to take the challenge to do something that hasn't been done before, and take this build to the next level.

Here's my RS6 steering wheel with paddles for the air ride control. I got it brand new on eBay for $800 shipped. I also wanted the OEM RNS-E Navi so and picked that up used on eBay for $400, which I was super stoked about.
http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Start/Avantbuild_Start-7.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Start/Avantbuild_Start-7.jpg.html)


Dorbritz Designs, based in Texas, hooked me up with my parts for the air ride build. Huge shoutout to Drew for answering a lot of questions and making sure some of my custom order parts were done properly and shipped quickly. Thanks homie! [up] [up] [up]
Got my dual Viar 444c compressors and Accuair tank mounts and VU-4 controller mount.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Start/Avantbuild_Start-8.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Start/Avantbuild_Start-8.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Start/Avantbuild_Start-9.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Start/Avantbuild_Start-9.jpg.html)

This is Nikkor, posing with my new car parts. [:)]

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Start/Avantbuild_Start-11.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Start/Avantbuild_Start-11.jpg.html)

Here I got my shipment of Accuair parts! I looked at Airlift struts and a few other options, but really liked the Accuair B8 Sport Kit they developed as a bolt on the B8 platform. They use their own bag design that has a progressive spring rate you can change and is designed to use the stock struts. Accuair said they were developing a kit for the B7 soon...... that was supposed to be ready for launch in November, but by January it still wasn't ready, so I decided, how hard could it be to retrofit the B8 Sport kit to the B7... lol

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Start/Avantbuild_Start-14.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Start/Avantbuild_Start-14.jpg.html)




Next I started doing some measurements for the wheels. At this point I didn't know what wheels I wanted, but I wanted to go flush. Here I'm using string and weight to measure how much room I have from the lip of my stock 18x8 et 40 to the fender. Using that measurement I could then do some calculations to determine exactly what width and offset I would need to flush with the fenders and still clear the stocks.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Start/Avantbuild_Start-5.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Start/Avantbuild_Start-5.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Start/Avantbuild_Start-6.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Start/Avantbuild_Start-6.jpg.html)

#Avantbuild
05-09-2014, 09:58 PM
STEERING WHEEL:

Here's the wheel before I took it apart. There's a lot of build threads of disassembly of these wheels so I won't waste time with details, but I will tell you that the chrome ring literally just needs to be pulled off. Careful though, its finish can be messed up easily, even if you use a small screwdriver, so take your time, work the edges and pry it off.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-1.jpg.html)

Here's the ring coming off.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-2.jpg.html)

If your wheel is a MFSW then look out for these white clips located on both sides of the wheel spoke underneath the airbag cover.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-3.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-3.jpg.html)

I then started my analysis of the paddle shifter system and used my DVM to test the resistance of the wires to figure out what wires I need to run through the clock spring.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-4.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-4.jpg.html)
http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-7.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-7.jpg.html)

Here my DVM is showing Overload, because at the moment I'm sending a very small voltage through a series of wires but there is no connection between them. Theoretically, when I push the paddle shifter, the circuit would be complete and you should see a small ohm reading showing you an electrical connection and what kind of resistance you have between those two circuits.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-10.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-10.jpg.html)

Here I'm completing the circuit, and my digital voltmeter is showing a reading of 0.3 ohms resistance. This is good. [up] Now we know that the two wires I'm connected too complete a circuit and can be extended through the clock spring and eventually wired to control the air ride ride height levels.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-9.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-9.jpg.html)

Next I soldered the wires and put heat-shrink wrap over them to keep them from short-circuiting each other.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-16.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-16.jpg.html)
http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-17.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-17.jpg.html)
http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-18.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-18.jpg.html)
http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-19.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-19.jpg.html)

Using a Torx I tightened the airbag back into position.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-21.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-21.jpg.html)

Here's the wheel re-assembled and ready to put in the car...... or is it?....

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-23.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-23.jpg.html)


I went to install the wheels and it turns out that the airbag wiring harness is slightly different than the harness on my OEM harness.. As you can see in this picture.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-32.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-32.jpg.html)
http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-33.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-33.jpg.html)


***DISCLAIMER***
What I did here I did at my own risk and fault. I am not responsible for what you might do to your own vehicle. This is solely a guide to my own experience and what worked for me, please do your own research and testing before blindly following someone else's steps.


Okay, so when working with airbags you have to be very careful. The green and orange plugs on the back are the actuators that when receiving a voltage, even a small one, will deploy the airbag. You can deploy your airbag by using a voltmeter, that's how sensitive they are. So when I tested this harness the first thing I did was to unplug the green and orange plugs, that way there was not way I could generate a voltage, even a small on that would come in contact with those deploy circuits.

In the picture above, with the pink harness, is the one that fits the clock spring in my car. Doing some online research, most MFSW conversions people buy a new clock spring that is compatible with their wheel and airbag. I was ignorant at the time of purchase and didn't realize I needed that, so I decided to try my own route and retrofit my own harness.


After testing the wire leads on both harnesses I discovered that the airbag wires were in the exact same places on each harness connector. Furthermore, the green and orange connections to the deploy circuit on my OEM harness FIT the new airbag. Looking a little more I discovered that the only difference between the harnesses was the ground locations! Piece of cake. So here I'm modifying both harnesses by slicing and dicing each one to create one super harness that fits my old clock spring, but plugs into the new RS6 MFSW and airbag. [up]

Here I cut the ground off the RS6 connector and soldered it in place of the smaller ground on the A4 one.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-34.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-34.jpg.html)

Here's the finished product, of soldering the three large grounds on the OEM harness. (OEM one had two small grounds originally)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-46.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-46.jpg.html)

#Avantbuild
05-09-2014, 09:58 PM
STEERING WHEEL: Part 2

What I did next was try to find a way to run the wires I extended out of the back of steering wheel (the ones I soldered to the paddle shifter circuits) to go through the clock spring, that way when I turn the wheel opposite lock the wires are crimped and cut. Fortunately, taking a closer look at the OEM airbag harness there were 3 wires unused. I needed 4, because two go from each paddle shifter. So I stole one more wire terminal from the RS6 harness I've been stealing everything else from and then I had 4 empty slots to solder my paddle shifter wire extensions too, which will now run seamlessly through the clock spring like it was supposed to be there in the first place.

Here I'm pulling one of the terminals out of the RS6 connector.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-38.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-38.jpg.html)

Here I've plugged it into the OEM connector (Red wire)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-39.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-39.jpg.html)

Audi/VW is weird in their wiring where they never put wiring sequences in numerical order.. so the 3 wires that were vacant on the other end of the connector, here at the clock spring harness connection were not even next to each other.. lol I tested this a triple check everything with my DVM before I cut any wires.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-42.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-42.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-43.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-43.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-44.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-44.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-47.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-47.jpg.html)

Here I've soldered the 3, now 4, empty wires to the paddle shifters.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-48.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-48.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-49.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-49.jpg.html)

At this point it was ready to be installed in the car. I wish I had a picture of me doing this, but I was very nervous about hooking up the battery and starting the car for the first time. Since I modified the original harness, I didn't know if the deploy sensors were so sensitive that a slight difference in resistance due to solder or some other reason would cause an airbag fault, or God forbid a full deploy in my face. So I was laying across the passenger seat staying as low as possible for fear of a deploytation while a friend was laying on the ground on the driver side pushing in the clutch while I started the car. It was a very tense and dramatic few moments.. but to much surprise nothing happened that wasn't normal. AND, there wasn't even an airbag fault light. BOOYAH! [up] [up] [up] [up] [up] [:D]

Unfortunately the functions on the steering wheel didn't work on their own.. but I was pretty sure it was just a coding issue.


Next I hooked up using Ross Tech's VAG Com cable and went to work. I had several faults, none were on the airbag side, that circuit was 100% good to go, but the faults were in the steering wheel controls, and functions. Also, my horn didn't work. This didn't make any sense to me cause it's a mechanical connection through the clock spring to activate. So I pulled it back out, and found that I accidentally swapped the grounds during the install. With that figured out the horn worked perfectly. I then went into vag com and recoded my ecu to the new mfsw and the functions I desired.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-50.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-50.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-51.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-51.jpg.html)

Here's the finished product! All functions work like it came from the factory, plus I have the paddle shifters ready to hook up to the air ride!

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-52.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Steering%20Wheel/Avantbuild_Start-52.jpg.html)

#Avantbuild
05-09-2014, 09:59 PM
TRUNK: Part 1

Browsing over different social media I've seen some really cool air ride builds. I love a good trunk setup with hard lines, hard wood floor, etc. However, the purpose of this vehicle was to have a daily driver that had space for my photography gear. I lay my seats down often, so even flushing a 5 gallon tank up against the back row wasn't really something I wanted to do. So, since I am retrofitting the Accurair B8 Sport Kit, which has most of the components designed to fit in the spare wheel well I got an idea. Why don't I put everything underneath the floor. Problem was, the spare wheel well wasn't big enough, its an awkward shape the isn't even symmetrical, plus is has a huge cone sticking up from the bottom side holding the EVAP system.. So I thought maybe I can make a false floor, putting a circular tank into the wheel well and then hiding the compressors under neath a raised floor. This still defeated the purpose of keeping the entire trunk space accessible.

This is why I decided the best way to do this was to cut out my spare wheel well and build my own custom box.


Here's what the trunk looks like empty.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-1.jpg.html)

Here's the awkward shape I was talking about, which houses the EVAP canister underneath.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-2.jpg.html)

This is looking up from underneath the car, showing the EVAP canister housed under the spare wheel well.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-7.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-7.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-8.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-8.jpg.html)

The first order of business was to re-route that canister. EVAP is important, so I didn't want to delete it. Yes, I could code it out with Vag-com so I wouldn't get a CEL but it plays an important function in our vehicles routine, so I decided to relocate it. Thankfully, Audi decided that they would put an empty space right underneath the ABS module on the driver-side rear trunk area, behind the interior trim that fit the EVAP canister perfectly. So I cut out the steel tubing and ran new hoses through a grommet in the frame to the new location of the canister. Can't even smell fuel inside the car so I think it was a success. No CEL either! [up]

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-9.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-9.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-10.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-10.jpg.html)


Next I proceded to mark out where I actually wanted to cut. Looking underneath the car I made sure not to mess with structural integrity areas like the frame, so I stayed clear of that and cut just inside of the frame rails, leaving me a nice area to weld in the new box I was going to build.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-11.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-11.jpg.html)

Here I'm using a laser level to help guide my cut.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-13.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-13.jpg.html)

Here I've completed my cut.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-14.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-14.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-15.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-15.jpg.html)

So scary!! There's no going back now!

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-16.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-16.jpg.html)

Next I started marking out my cut and bend lines on the new sheet metal I picked up to form the box. I got 11 ga. mild steel. (For future reference, 11 ga was probably a little overkill. I jumped up and down inside the box afterwards and it didn't even think about budging. If it's just holding air ride components you could probably get away with 13 ga, maybe even 15 ga for light purposes.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-22.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-22.jpg.html)

I used a plasma cutter to cut the 4x8' sheet to size.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-25.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-25.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-27.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-27.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-28.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-28.jpg.html)

Here I'm using a press break to bend the sheet into the shape of a box. Unfortunately we could only get two side to 90 degrees and the other two to 45, so we had to bend the rest by hand.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-29.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-29.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-30.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-30.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-31.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-31.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-34.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-34.jpg.html)

Here it is after bending the rest by hand.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-35.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-35.jpg.html)

Next it was time to put the box back in place and weld her in!

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-36.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-36.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-37.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-37.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-38.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-38.jpg.html)

As I lifted it in place the first time I realized that I didn't take into account the fuel filler neck.. so I made a design adjustment and cut out a section.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-40.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-40.jpg.html)

Here it is sitting in place before I tacked it up.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-41.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-41.jpg.html)

Tacking the sides

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-42.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-42.jpg.html)

All welded up!

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-44.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-44.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-46.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-46.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-49.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-49.jpg.html)

#Avantbuild
05-09-2014, 10:00 PM
TRUNK: Part 2

Next I filled the gaps inside the car (the areas that held the tool kit for the spare wheel) with expanding foam.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-50.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-50.jpg.html)

Shaved the foam after it dried.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-51.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-51.jpg.html)

I also sprayed a rubberized coating on the bottom of the box to keep any of the welds from rusting but also to weather-proof it even more (just in case there were any small holes in my welds).

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-52.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-52.jpg.html)

Still retained the stock tow hook. [up]

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-53.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-53.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-54.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-54.jpg.html)

I coated the inside as well. Now it's starting to look like we're getting somewhere![:d]

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-56.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-56.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-57.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-57.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-58.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-58.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-59.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-59.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-60.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-60.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-62.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-62.jpg.html)


I then lay'd in some sound deadening material, so reduce not only road noise but to try and help absorb some of the compressor rattle when filling the tanks. I got this from www.b-quiet.com and am super impressed with it. Extremely affordable too! I was easy to lay in, cut with a razor blade, and malleable over trunk lines.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-64.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-64.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-66.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-66.jpg.html)


At this point I started to build the platform for which I would mount the air ride components. Tanks, compressors, VU-4 controller, etc. I thought about just bolting everything to the floor, but having bolts sticking out through my nicely made box didn't sound appealing to me. Plus, I knew that bolting two compressors to a metal base would be a perfect case of the rattles, so I decided against that. I took this into account when I fabricated the box depth. I know that if I used a 5/8" board and fastened that to the bottom of the box I would have enough clearance for all the components I had chosen.

So I got a small sheet of 5/8" MDF at my local Home Depot. (There was a time in this project where I was going to Home Depot every single day for almost three weeks!!! Pathetic. lol

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-121-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-121-1.jpg.html)

I also glued in some rails that will be my base mounts for the new floor going in. I know it looks really raised up, but there is actually a lot of wasted space under the A4 Avant floor and my new floor will sit at exactly the same level as the OEM one.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-126.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-126.jpg.html)

Here I've cut the base board to size.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-124.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-124.jpg.html)

For a little side project while the glue was drying I grabbed my brand new shiny chrome compressors and threw them in the bead-blaster. I'm not a chrome guy, and wanted a more subdued look.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-127.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-127.jpg.html)

To this point I still didn't know the orientation of how I would install the tanks and compressors. I had a vague idea, inspired by Accuair's 2012 SEMA build, that didn't actually end up working out, but at the moment I was at square one for layout. Pretty stupid since I cut my box and welded it in.. permanently.. so I was really frustrated when I started messing with my parts that it didn't fit.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-129.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-129.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-132.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-132.jpg.html)

In this picture you can see the Accuair EXO tank mounts and compressor mounts. Clearly, this setup would not work. [headbang]

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-67-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-67-1.jpg.html)

My mood was quickly changed however when I unwrapped my (2) 3-gallon tanks I got through Dorbritz Designs sourced from Specialty Suspension. They had just come out with their brand new D.O.T. approved seamless air tanks, and I had to have them. I also had them hydro-dipped in a wood grain. [drool][race]

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-69.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-69.jpg.html)

I decided to built a template of the trunk box to start fitting parts to try to find a solution.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-80.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-80.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-83.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-83.jpg.html)

#Avantbuild
05-09-2014, 10:00 PM
TRUNK: Part 3

After much frustration I thought I had been defeated and was devastated to go to plan B. Which would not be good because it meant selling my beautiful tanks (I actually had them up for sale on Audizine for a day) and buy a single 4-gallon tank instead. However, after doing some preliminary measurements I discovered that the 4-gal tank was literally 3/4" too wide to fit in the box.. so I was hosed. So I was pretty bummed one night, but the next day I had an idea and went into the shop to test it out.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-106.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-106.jpg.html)

Here I found the orientation of the tanks and compressors that I liked.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-84.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-84.jpg.html)

The culprit to my frustration was this VU-4 Controller mount. So I bend it to a 90 degree instead of the 45 it comes at.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-78.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-78.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-87.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-87.jpg.html)

I also used a 1/2" spacer on the tank closest to the tail of the car and that gave me enough clearance for the controller. [up]

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-85.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-85.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-86.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-86.jpg.html)

Here's progress on the compressors.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-71.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-71.jpg.html)

Much better.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-72.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-72.jpg.html)

I also didn't know what I wanted to use for the finish of the box. At first I thought I'd just use heavy duty carpet, or maybe even fiberglass something, but in the back of my head I knew I always wanted to have hard wood somewhere in my car. So, the search began. I ordered some samples online but quickly discovered it's really hard to find a nice hardwood supplier that will sell you 25 sq/ft. lol Lucky for me, my automotive professor, Rob Hom, who btw is one of the greatest men to walk this earth and a huge inspiration and role model for me, had some extra bamboo left after his house build. Perfect. I'm sure its been done before, but I've never seen bamboo in a car before, so I figured it was the perfect material. It also has such a light finish that it contrasts the wood-grain tanks very nicely. [up]

So I started laying out the pieces.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-74.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-74.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-76.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-76.jpg.html)

The cool thing about this is that all the pieces match. I cut them so the grains follow each other starting for the back of the trunk to the floor and then up the other side.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-77.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-77.jpg.html)

After cutting my pieces I brought them out and glued them to a thin piece of birch-ply.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-79.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-79.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-88.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-88.jpg.html)

We use weights to simulate human occupants while we do alignments so I borrowed those for a night to keep my floor boards nice and flat.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-89.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-89.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-92.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-92.jpg.html)

Here it is sitting in the car.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-93.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-93.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-94.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-94.jpg.html)

Test fitting the components!

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-95.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-95.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-101.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-101.jpg.html)

Progress on the wood sides

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-104.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-104.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-105.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-105.jpg.html)

Starting the drill holes and bolt the tanks and compressors down! I left tape on the top to help protect the finish while I worked.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-108.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-108.jpg.html)

I used these cool threaded sink nuts that will allow me to thread in bolts from the top and have a flush bottom.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-111.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-111.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-112.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-112.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-114.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-114.jpg.html)

Used grommets to protect the power and ground wires from the compressors, but also to hide the wiring underneath.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-115.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-115.jpg.html)

#Avantbuild
05-09-2014, 10:01 PM
TRUNK: Part 4

Test fitting.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-117.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-117.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-118.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-118.jpg.html)

The disaster of a work station. [wrench]

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-121.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-121.jpg.html)

I got some Accuair stuff in to rep while I worked.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-119.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-119.jpg.html)

I also decided to tuck the VU-4 wiring harness since there are 12 wires, and I didn't want those to be just sitting around the nice box, so I measured out the length I'd need to extend the wiring harness and soldered an additional 6' of cable. Most installs put the E-level controller in the main compartment where the VU-4 controller is, which is why the harness is so short, and I had to extend mine.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-10.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-10.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-9.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-9.jpg.html)

Here's the completed extended harness.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-11.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-11.jpg.html)

Now that I have the harness ready I could run the wires through the bamboo floor.

http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-3.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-3.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-4.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-4.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-5.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-5.jpg.html)

I used heat-shrink wrap to clean up the harness.

http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-2.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-7.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-7.jpg.html)

Here's the underside of the floor.

http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-8.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-8.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-9.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-9.jpg.html)

Test fitting in the box.

http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-10.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-10.jpg.html)

Finishing touches

http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-12.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-12.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-13.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-13.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-14.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-14.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-16.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-16.jpg.html)

All of this is hidden underneath. [up][up][up][up][up][up]
http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-17.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-17.jpg.html)

About to be glued in for the last time!

http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-19.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-19.jpg.html)

Using weights to help keep it in place overnight.

http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-20.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-20.jpg.html)

#Avantbuild
05-09-2014, 10:01 PM
TRUNK: Part 5

Now that it's glued in I needed to finish the wood siding.

http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-21.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-21.jpg.html)

Angles [>_<]

http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-22.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-22.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-23.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-23.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-26.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-26.jpg.html)

Finished!

http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-27.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-27.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-28.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-28.jpg.html)

Now for some carpet to cover up the wires and sound deadening material.

http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-29.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-29.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-30.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-30.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/Trunk%202/Avantbuild_Trunk-31.jpg (http://s432.photobucket.com/user/kurtislee_1/media/Trunk%202/Avantbuild_Trunk-31.jpg.html)

E-LEVEL:

Since I re-located the E-level controller I had to run all the wires to the new location. Remember that spot where I re-located the EVAP canister? Well, turns out that there's a perfect gap above that but underneath the ABS controller to mount it. So here is a few pictures of the new mounting location and all the wires involved.

Here's the list of components I installed:

(1) E-level controller
(2) Harness to VU-4 Controller
(3) Pressure sensor switch to the tanks
(4) iLevel wifi controller
(5) Key Fob antenna
(6) Rocker switch for ride height selection

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-4.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-4.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-3.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-3.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-2.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-7.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-7.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-6.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-6.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-5.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-5.jpg.html)

Next I ran the wiring harness for the rocker switch through the interior and up into the dash. Sorry I didn't take any pictures of the tuck under the carpet.. but I basically ran it under the door sill all the way to the dead pedal and then up underneath the dash and into the Head Unit area.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-1-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-1-1.jpg.html)

Using radio keys (DO NOT try to pull your radio without these... please.... you'll mess it up. lol)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-2-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-2-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-3-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-3-1.jpg.html)

This little plastic tray is a pain in the arse to get out, but using small screw drivers you pop the tabs down from the top and it slides right out.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-4-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-4-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-5-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-5-1.jpg.html)

Using my dremel to shape the plastic tray to accept its newest component.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-6-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-6-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-7-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-7-1.jpg.html)

BAM!

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-8-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-8-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-9-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-9-1.jpg.html)

Reno Heon, Co-Founder of Accuair informed me that you can pop out the windows and replace the arrows to a different orientation, that way you can have the switch laying horizontal like I do but have the arrows point up and down. I have done this yet, but it is possible.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-10-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-10-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-12-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_Elevel-12-1.jpg.html)\


RNS-E

I also took the time to install the RNS-E I purchased on eBay. Unfortunately the previous owner did not supply the radio code with the unit, and you can't pull it from Vag-com, so after installation I drove to VW/Audi Overturf dealership in the Tri Cities. They should've been able to use their factory scan tool to pull the radio code, but they told me that I did something wrong, and their machine wouldn't communicate with it and there was nothing they could do, and that this conversion wasn't even possible to their knowledge. Well, I knew it was possible, and also knew that I had installed it correctly, so 3 hours later and after paying my $100 diagnosing fee I called Audi of America directly. Gave them my RNS-E S/N# and my vehicles VIN and after a 4-minute conversation I had a perfectly working RNS-E HU. Not trying to bag on a local dealership, but I probably won't be returning for any kind of service or diagnosis anytime soon. [down]

Here it is installed.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_RNS-E-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_RNS-E-1.jpg.html)

BOOM: installed correctly and coded.


http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_RNS-E-1-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Elevel/Avantbuild_RNS-E-1-1.jpg.html)

I did have to go into Vag-Com to code my ecu to recognize the different head unit and assure it that the Nav was there and whatnot, but now it's a completely functional unit that works with 100% functionality.

#Avantbuild
05-09-2014, 10:02 PM
EXHAUST

So remember how I cut out the spare wheel well and replaced it with a rectangular box? Well, when I did that I made sure I measured for the stock exhaust mufflers to fit. After I welded in the box I test fitted the mufflers.. and they did technically fit, within a 1/4" on each side.. but that was a little too close for my comfort. I don't like rattles and knowing that when I go around a tight corner that my muffler is going to slam into my box wasn't something I was really looking forward too. So, I decided to cut my losses (which in my mind there really weren't too many - but let me explain). I had a 98 Db exhaust on my R32 which I loved. It purred like a kitten around town but roared like a lion when I got on it, and in College Place, I'd have people texting me from their homes 2+ miles away asking if I was driving around. That was fun, but it didn't make me very popular with the CPPD. Well, not the popularity I enjoyed rather. I bought my Avant in June of 2013 and have really really enjoyed the quiet ride and even more so the lack of police attention. That being said, I think the A4 could be a little more throaty, and removing the mufflers would reduce the size of the resonating chambers, giving me a little more sound. So, that's the first [up]. The second is that each muffler weighs almost 30 pounds!! That's just stupid. So, cutting the mufflers out, adding a straight pipe section to each side and welding on my own tips were what I chose to do. I think kit exhaust systems are great. They fit, they've been researched to sound good, but they're expensive. I didn't have the cash flow to drop $700-$1200 on a bolt on exhaust.. so I didn't. I cut the mufflers, used coat hangers to replicate the bends I needed and had a local shop mandrel bend two pipes for me. I then measured the spacing of the quad tip rear valence to get the maximum size tips without rubbing a purchased those. In the end I spent $150 on mandrel bended pipe and the quad tips. [up]

Here I am dropping the stock system.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-2.jpg.html)

Here I've cut out the mufflers and tacked in the bended straight pipes. I only added approximately 2.5-3' of pipe on each side.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-4.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-4.jpg.html)

When I cut out the spare wheel well I had to cut through where the stock exhaust hangers were. So I had to reposition them. I chose a spot a little further back and welded in some bolts that I could thread the oem hanger on, then used the oem bung and welded that to the new piping.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-9.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-9.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-6.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-6.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-7.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-7.jpg.html)

I bought these tips from Red Tail Performance. Here's the link: http://www.redtailperformance.com/exhaust-muffler-tip-dual-round-staggered-forward-slash-cut-rolled-edge-2-5-inlet-id-3-outlet-od-9-5-length-6-25-outer-width-rtp-037lr/

I got them 4 days later and was very impressed. Theses are solidly built and professionally packaged. Big shoutout to Red Tail Performance for these. [up]

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-8.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-8.jpg.html)

Here I've taped the tips to keep them nice while I position them to tack them in place.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-10.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-10.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-11.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-11.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-12.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-12.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-13.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-13.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-14.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-14.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-15.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-15.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-16.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-16.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-17.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-17.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-18.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-18.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-19.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-19.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-20.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-20.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-21.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-21.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-22.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-22.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-23.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Exhaust/Avantbuild_Exhaust-23.jpg.html)

I'm really REALLY happy with how these turned out. They sounds great! Cold idle is really throaty but when the secondary air turns off and it drops down to normal idle rpm it's as quiet as stock. It doesn't resonate in the car until 3,300-3,500 rpm and stops around 4,200 under WOT, so it's not awful. I haven't really done any freeway miles since I've put it on, so I can't tell you how loud the cabin will be at 70 mph, but I'll keep that in mind when I do and let ya'll know. In my opinion (and please allow me to do so) this is a great alternative for those of you who are on a budget but want the look of the S4 quad tips and a slightly more throaty sound without spending a grand. There, I said it. Sorry APR lol. That said - obviously this isn't to their quality standard, nor any scientific testing/R&D, but it works, it looks super good, and doesn't rattle. For me, this was a success.

Audi_509
05-09-2014, 10:13 PM
This should be interesting. Great start by the way.

Wally World!

#Avantbuild
05-09-2014, 10:31 PM
This should be interesting. Great start by the way.

Wally World!

Thanks! I'm excited to share my progress. [up]

#Avantbuild
05-09-2014, 10:31 PM
TRUNK: Part 6

After the exhaust was taken care of, the E-level controller mounted (I'll post more pictures of the actual mounting location later) and the wires run, the glue had completely set in my box and I could start the process of installing the tanks and hard lines. I did a lot of research, and when I mean research I actually mean searching, to find information on hard lines paired with PTC (push-to-connect) fittings and what metal types are compatible with these fittings. There are a lot of opinions online regrading hard lines with PTC vs flared fittings but not a lot of facts, that I could find. There's a lot of pictures of show cars with immaculate hardline setups, most seemingly with stainless steel lines, but there's not a lot of report on whether these setups are working as designed, if the owners have trouble with leaks, etc. So, after doing some research that never really brought me to a solution, I decided to step out in faith and go with a hardline setup using copper and PTC fittings.

After inspecting the PTC fittings up close (I bought the SMC ones from www.bagriders.com) I discovered that there are small teeth that extend from inside and "grab hold" of the O.D. of whatever material you stick inside. Obviously, these are designed for the nylon airline. However, are some trial and error, I have gotten some great results using memory cloth around the O.D. of the copper end, (also making absolute sure that it's completely round and cut square), that these ends are a good combination with the PTC fittings. If you pull the copper end out of the fitting you will see marks from the teeth imprinting on the surface of the soft metal. That being said, I would fear to use a ferrous metal (Stainless steel, Mild Steel, etc). I don't think that these "teeth" in the PTC fittings would be able to grab hold enough of the line and unless there is tension from the route of the bends these would be prone to shift in position, which could easily stem a small leak.

Surprisingly, (2) of my SMC PTC 3/8" straights were defective, so I called up Bagriders.com and asked them if this was something that happened often, but they assured me that this was an extremely special case that and they had never had issues with these PTC fittings before. So, BagRiders was nice enough to send me some replacement fittings and then I was good to go, so a huge shoutout to www.bagriders.com for hooking me up with fantastic customer service, quick shipping, and supplying the parts I needed. [up] [up] [up]

SO! Here we are, test fitting the VU-4 controller on the tanks in the box.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-1-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-1-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-2-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-2-1.jpg.html)

Starting the copper bending. I had a good idea of routing I wanted to take with the lines already (thank you slightly slow History class at 8:00 am) so I got right into the bending.

**NOTE**

I wasted about 6' of copper because I put it right in my hand bender and crimped. If you're like me, and are not wanting to have major crimp marks in your hard lines, then you can't just put the piping in the bender and expect the O.D. to remain the same across the bend. Copper is an extremely soft metal, you can easily bend it with your hands, and the O.D. is easily manipulated but extremely difficult to "bring back" so to speak. So, I talked with a friend who is a machinist and he suggested that I fill the copper with something, thus helping keep the original outside diameter when bending. So I went to home depot and bought a bag of playground sand for $5. They only come in 50lb sacks... Oh, btw I bought all my copper from Home Depot too. It's extremely expensive to buy copper straights (which is what we all want to start with for our bends) so I decided to make my own. I actually bought a 3/8" copper straightener from the UK that developed this product using kickstarter. I could not find any other viable solution from the US market, which really surprised me, but this device is genius, and relatively affordable, and creates extremely straight bends out of your coil of copper - which is what I bought from home depot (I just got the 3/8" O.D. 20' coils of copper used for refrigeration or compressed air - $1.50/ft I believe).

So, after sliding these sections of coils through the straightener, I plugged one end of the straight and filled it with sand, tapped the ends to keep filled air gaps inside, and really shoved as much sand inside my tubing as possible. (If there are any air gaps inside then it completely defeats the purpose of putting anything in there because as soon as you start your bend the sand shifts to the low pressure area and you still get your crimped O.D. marks. So, I filled them with sand to the brim and then some and capped both ends when done. Then I would put it in my hand bender and it made dramatic changes in my bending results. It's not a perfect system, but it's a lot closer to what I wanted. Stainless Steel lines seem to be used for perfect looking O.D. bends, but SS is extremely expensive and much harder to work with.

This is the straightener device I used. It's such a simple machine its brilliant. Just 16 bearings at 90 degree offsets to each other that keep the O.D. of the pipe when shoved through. [up]
It's called a Kwix, from the company http://www.kwixuk.com and I got the 3/8" O.D. tool. Shipped price was $80 I think? I was very pleased, to say the least. A huge shoutout to KwixUK for making a brilliant product.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-18.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-18.jpg.html)

Just shove the end through like this.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-19.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-19.jpg.html)

Bam, a straight pipe.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-20.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-20.jpg.html)

So here I've started the first line.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-3-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-3-2.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-4-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-4-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-5-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-5-2.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-6-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-6-2.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-7-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-7-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-8-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-8-2.jpg.html)

Marking the lines for a 90 turn. (Note, this image shows the first set of lines I make WITHOUT using sand, so you can see bend marks near the inserts on the VU-4.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-9-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-9-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-10-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-10-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-11-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-11-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-12-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-12-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-13-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-13-1.jpg.html)

Here I'm marking out where the bulkheads will go. Somehow you need to get the compressed air out from your VU-4 controller to your bags, and doing so means passing to the outside of the vehicle at some point. I REALLY wanted a box in the trunk that was rectangular in shape and uniform.. but the fuel filler neck kept me from doing that and gave me that 45 angle on the upper right hand side.. So I figured that I might as well use that not a design flaw, but with purpose. So I'm going to put the bulkheads along that 45 to pass the lines to the outside, where they will switch material to nylon lines.

Here I am using the bulkhead threads to help visualize where the lines would be situated on the 45.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-14-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-14-2.jpg.html)

Here I've marked where the holes are going to be.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-15-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-15-2.jpg.html)

Using a unibit I started drilling.....

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-16-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-16-2.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-17-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-17-2.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-18-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-18-1.jpg.html)

And then disaster struck.......
The unibit wasn't quite large enough to drill the O.D. for the bulkhead, so I started using a dremel to help enlarge that diameter just a tiny bit and my hand slipped and my bit went straight through the filler cap to the gas tank.. Gas started dripping everywhere, and I knew it was over. So I started researching what I'd need to do to correct the problem, and book time to drop the tank is just over 7 hours.. Not to mention, the filler neck and gas tank is a one-piece unit, costing over $1,100.... I said, no way. I wasn't going to drop the tank unless I really had too, so I a really close look at the hole I made and it wasn't on the underside of the neck, more on the side of it, so I thought I'd give J.B. Weld's Waterweld a shot:
http://www.amazon.com/J-B-Weld-8277-WaterWeld-Underwater/dp/B000BRQ0TW
I'd heard good results from another mechanic that he uses this all the time for fuel tank fixes under 1/2" in diameter, and my hole was maybe 3/16" so I thought, why not. It's cheap and can't hurt to try. So I plugged the hole and waiting a day and it seemed to work!! YES. But, I thought it'd be a good idea to test me EVAP system to make sure it's all sealed up, so I went into VAG-com and did a complete fuel-tank and EVAP system check and this is what I got. Hallelujah. [hail]

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-30-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-30-1.jpg.html)

#Avantbuild
05-09-2014, 10:32 PM
TRUNK: Part 7

After fixing the hole I kept drilling, much more careful now..

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-19-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-19-2.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-20-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-20-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-21-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-21-1.jpg.html)

Tank sitting in there, oooooh so pretty. [up]

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-22-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-22-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-23-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-23-2.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-24-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-24-2.jpg.html)

I wasn't sure I would like the wood grain tanks with the copper lines, but now I'm kinda digging it. However, the brass fittings on the bulkheads were too much. Also, the hex head shape didn't cover the drill hole O.D. so I had a friend of mine help me machine and thread some new nuts. Thank you Tosh, you're the man. [hail]
I then plasti-dipped them flatblack and threaded them on the bulkheads and was much happier with the finish than the brass hex nuts.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-25-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-25-2.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-27-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-27-2.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-28-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-28-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-29-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-29-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-31-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-31-2.jpg.html)

I made sure to use the recommended loctite for the PTC's.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-32-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-32-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-33-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-33-2.jpg.html)

Pulled the lines out to clean the box from saw dust and other particles.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-34-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-34-1.jpg.html)

Here's all the lines installed and the Mead mufflers plugged into the VU-4.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-35-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Trunk/Avantbuild_Trunk-35-2.jpg.html)

I finished the lines around 4:30 am on Sunday, April 27, just in time to roll it out for the Walla Walla University Alumni Car show. The University's Auto Club has a food booth and all of us students bring out rides out to show what we got in comparison to the brand new Corvettes and wide-body Austin Mini's that the alumni brings to show. lol
I popped the trunk and displayed the front struts along with some Accuair brochures to help educate the public haha. I only got asked if the tanks were for NOS once, which I was really surprised about. Ha! [up]

Here I am representing my new MRR Wheels GF6 19/9.5 et +15 with Accuair gear.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Start/Avantbuild_Random-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Start/Avantbuild_Random-1.jpg.html)

#Avantbuild
05-09-2014, 10:33 PM
WHEELS & FITMENT

So, back in 2013 I was trying to find a set of wheels that would really change the characteristics of this wagon into a stance'd beast. I went to SEMA 2013 and looked very hard for a pattern I that I thought would be perfect. Unfortunately, most of their builds are featuring Adv.1 which are 8-12k for a set. Not even remotely a possibility for me. I really wanted a set of Rotiform IND's, but couldn't afford the 3-piece set either. I started searching for wheel manufactures that are "up and coming" that I could afford, and I found MRR Wheels. I contacted them directly about my senior project for school and asked if they would be interested in doing a part sponsor for my project by helping me get a set of wheels, and they very kindly replied almost immediately that they would love to do that, but I should really apply for their scholarship contest they were having. Scholarship? Well, in Oct-Nov they held a scholarship giveaway of $5,000 for five students in the automotive industry. I wrote an essay and submitted my application for approval and it was shared on their instagram and FB page for our friends and families to support each applicant, and at the end of November I got the notification that I had been chosen to represent MRR with their $1,000 scholarship! So I put the check on my school bill and that gave me the freedom to buy a set of wheels from them, and shipped I paid just over $1,100 for a set of 19x9.5 et+25 front and et+15 rear deep concave MRR GF6's. So, huge shoutout to MRR Wheels for catering such a fanatic scholarship program for Automotive students, and hooking me up with an amazing set of wheels that are going to give me the aggressive look I want so badly. Thank you!!! [up] [up]

That said, lets get into the fitment process a little bit.

Unboxing the new wheels.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-3.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-3.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-2.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-4.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-4.jpg.html)

I did a lot of calculations to figure out my offset. I didn't want to use spacers, so by using basic math and accurately measuring my stock wheels I was able to calculate the measurements needed to get the stance I wanted.
This fitment was done back in January, so I hadn't done the exhaust yet or even cut the trunk out, but I removed the front and rear springs to test fitment.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-6.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-6.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-7.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-7.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-9.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-9.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-10.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-10.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-11.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-11.jpg.html)

Taking apart the front upper control arms were a pain because there was a lot of sand and gunk sitting in where the bolt slides through the receiver on the top of the steering knuckle that holds the two pins connected to the control arm.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-12.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-12.jpg.html)

Using a prybar I was able to get the pins out hitting them with a rubber mallet at the same time.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-13.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-13.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-14.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-14.jpg.html)

Gross

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-15.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-15.jpg.html)

Problem. My stock shocks don't go low enough.. I ended up buying the Koni yellow struts that are designed for lowered vehicles. Costed me another $250 shipped from ECS for the front two struts. According to Accuair, their B8 Sport Kit is designed to utilize the OEM B8 struts and they are capable of going low enough already, but I guess they're a slightly different design than the B7 ones, so I needed to replace them.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-17.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-17.jpg.html)

Here's the front passenger strut bottomed out with still 1.5" to drop still..

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-18.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-18.jpg.html)

Mounting the 1st set of tires, lol, using our Hunter tire mounting machine.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-20.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-20.jpg.html)

I got a set of Nitto Neo Gen 215/35-19 to get the stretch I wanted to sit the fender right between the tire and wheel lip, but the sidewalls were stiff enough that they would not mount on the rim in a way I was comfortable running. I tried blasting air to set the bead, I tried a dyno strap in the middle, I even did the dreaded start fluid tire stretching method. No dice. So I sent them back and got a set of Nitto NT555 225/23-19's and they mounted perfectly.

Here's the Neo Gen's

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-24.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-24.jpg.html)

Here's the NT555's mounted and test fitted in the front.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-34.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-34.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-29.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-29.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-31.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-31.jpg.html)

I'm going to pull the fenders just a bit to give me clearance to drop when I park.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-32.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Wheels/Avantbuild_Wheels-32.jpg.html)

Audi_509
05-09-2014, 10:53 PM
I can't believe I haven't seen you driving around. Do you happen to live in College Place instead of Walla Walla?

mec
05-09-2014, 11:07 PM
My hat off to you sir, what an idea, looks like it will be fantastic.

One bit of personal advice. Guys who do air ride make their controls far too easy to bump into, nudge, hit, press, you name it. The paddle shifter idea is fantastic, buttttttt....what happens when someone else drives your car and presses one of those and bottoms out the car destroying your wheels and oil pan and undercarriage? Or what happens when you are cleaning your car and accidently bump the switch, it sticks and you air out on startup, etc. Various scenarios where you destroy your car because the switches are too accessible. So why not install a killswitch so that the the paddle shifters only work once the primary switch is turned on?

Easy insurance.

#Avantbuild
05-09-2014, 11:12 PM
I can't believe I haven't seen you driving around. Do you happen to live in College Place instead of Walla Walla?

Seriously?? Yea I live in College Place lol. You haven't seen it cause it's not quite finished yet. [:D] I drove it for the first time today on bags around the block cause I don't have the height sensors in yet..

#Avantbuild
05-09-2014, 11:16 PM
My hat off to you sir, what an idea, looks like it will be fantastic.

One bit of personal advice. Guys who do air ride make their controls far too easy to bump into, nudge, hit, press, you name it. The paddle shifter idea is fantastic, buttttttt....what happens when someone else drives your car and presses one of those and bottoms out the car destroying your wheels and oil pan and undercarriage? Or what happens when you are cleaning your car and accidently bump the switch, it sticks and you air out on startup, etc. Various scenarios where you destroy your car because the switches are too accessible. So why not install a killswitch so that the the paddle shifters only work once the primary switch is turned on?

Easy insurance.

Cheers homie. [up]
It's a very valid concern! The cool thing about Accuair is that the "aired out" (parked) is not accessible while rolling. You have access to your 3 pre-saved ride heights, which technically should be at safe driving levels. The shifters will switch between the heights, and not a variable control. Does that make sense? Essentially, you could be cruising in (2) and click the right paddle shifter and it'll raise up to (3), then after the train tracks you click the left shifter and it'll lower back to (2). However, I love the idea of a kill-switch. Super easy to install, and that way it'll disable an accidental use by another occupant. Thanks for that, I appreciate it! [:)]

mec
05-09-2014, 11:20 PM
genius!

fly300kts
05-10-2014, 05:02 AM
Congrats, really impressed [hail]

Phil

geebus
05-10-2014, 05:36 AM
very cool stuff going on here! Makes me want to go to automotive school lol. And photography school. Looking forward to seeing the updates [up]

leftovers
05-10-2014, 06:31 AM
Cool build. I'm looking forward to the rest of the updates. You are very brave for cutting up the trunk like that. I don't think I would have done it. I would have found a way to work around it...I'm not sure how...I'm sure it would have been a compromise though.

PNW Avant
05-10-2014, 08:00 AM
Great thread. The only disappointment is that it was a great story with no ending! Looking forward to seeing the progress.

#Avantbuild
05-10-2014, 08:19 AM
Congrats, really impressed [hail]

Phil

Thanks Phil! I'll be updating more in the next bit here.

#Avantbuild
05-10-2014, 08:20 AM
very cool stuff going on here! Makes me want to go to automotive school lol. And photography school. Looking forward to seeing the updates [up]

Thanks man!! More updates coming soon. Thanks for checking it out! [wrench] [up]

#Avantbuild
05-10-2014, 08:22 AM
Cool build. I'm looking forward to the rest of the updates. You are very brave for cutting up the trunk like that. I don't think I would have done it. I would have found a way to work around it...I'm not sure how...I'm sure it would have been a compromise though.

Haha, I don't blame you one bit. I'd say I agree with you 100% except I've seen the results now that I'm mostly finished with the trunk and it was worth it. I definitely second and triple guessed myself while I was doing it though... [o_o]

#Avantbuild
05-10-2014, 08:23 AM
Great thread. The only disappointment is that it was a great story with no ending! Looking forward to seeing the progress.

Thank you! Sorry about that haha, I'm posting some new material very soon! [up][up][up]

CLEANA3
05-10-2014, 08:39 AM
Very nice , love the idea of the wheel.

jnm
05-10-2014, 09:26 AM
Looking great so far!

#Avantbuild
05-10-2014, 09:43 AM
Very nice , love the idea of the wheel.

Cheers sir! [up]

#Avantbuild
05-10-2014, 09:44 AM
Looking great so far!

Thank you! There's more stuff happening all the time, so stick around. [:D]

volcomic
05-10-2014, 03:06 PM
I'm excited to see the rest of this! Hopefully I'll get the chance to see this in person at some point on the LW cruise or Audi expo? I'm starting to think mine will end up on bags at some point as I get bored with it, but I can't say I'll have the balls to cut her up and make a custom setup like that. Nice work [up]

CassiesandraLee
05-10-2014, 04:51 PM
You're making me miss the 509! As well as the Walla Walla valley wine :)

Looks so great, wish I had your abilities!

CassiesandraLee
05-10-2014, 04:53 PM
Also, I went to many a swim meet at Walla Walla U back in high school, one of the best racing pools in Washington.

RAudiB7A4
05-10-2014, 06:12 PM
Nice work, nice build. Excited to watch it progress and see the finished product!

AKO
05-10-2014, 06:34 PM
Awesome stuff. Really love the quality being put in! Bring it to Leavenworth if you finish up by then

#Avantbuild
05-10-2014, 06:56 PM
I'm excited to see the rest of this! Hopefully I'll get the chance to see this in person at some point on the LW cruise or Audi expo? I'm starting to think mine will end up on bags at some point as I get bored with it, but I can't say I'll have the balls to cut her up and make a custom setup like that. Nice work [up]

Haha! Thanks man, I appreciate it. It was definitely tough to cut up a perfectly good vehicle. I am not sure I'll make it to LW because I'm graduating college the next day.. when and where is the Audi expo?

#Avantbuild
05-10-2014, 06:57 PM
You're making me miss the 509! As well as the Walla Walla valley wine :)

Looks so great, wish I had your abilities!

Yeahhhh 509 whattup! Thanks for the props, I appreciate it very much. [hail]

#Avantbuild
05-10-2014, 06:57 PM
Nice work, nice build. Excited to watch it progress and see the finished product!

Cheers sir, I can't wait to share the rest!

#Avantbuild
05-10-2014, 06:58 PM
Awesome stuff. Really love the quality being put in! Bring it to Leavenworth if you finish up by then

Thanks man! I wish I could go, but it doesn't look like my schedule will allow it. Where's a good way to find out about the Euro meets in the PNW?

mightemouce
05-10-2014, 07:10 PM
Looks Sweet!!
Some final results would be sweet!

datwagn
05-11-2014, 11:48 AM
this is fucking beautiful man, very impressive

http://replygif.net/i/95.gif

leftovers
05-11-2014, 01:14 PM
I found more progress on Instagram. I'm sure he'll get around to posting all the details though.

volcomic
05-11-2014, 02:10 PM
when and where is the Audi expo?

Look like it's June 21st this year (http://www.audiexpo.com/Audi_Expo/Home.html)

4RingRook
05-11-2014, 08:07 PM
This is awesome.

Capt. Obvious
05-11-2014, 08:52 PM
Cool build. Subscribed.

PNW Avant
05-11-2014, 10:10 PM
Not gonna lie it would have been really cool if you could have wired in some old allroad buttons for your ride height adjustment!

ShadowGLI
05-12-2014, 07:45 AM
so far great build, in for this one [wrench]

tankdeer
05-12-2014, 09:57 AM
Very cool build. We have an extremely similar trunk layout as yours except confined in the stock spare tire well. Oddly I don't have any good pictures of it, but here was one of our initial test fits with almost everything connected

http://distilleryimage9.ak.instagram.com/e78d2f0ca4f711e3afd412824b243569_8.jpg

I ended up extending the VU4 harness in a similar fashion to you, and mounted the ECU under the factory floor behind the rear seats

http://photos-b.ak.instagram.com/hphotos-ak-ash/925830_1499237530304929_1094753347_n.jpg

We're still in the process of getting everything cleaned up but it's been running and functional for a couple months and we're very happy with it so far. I'm sure you will be too.


I do have a couple questions though, specifically in regards to your paddle shifters. I'm curious how you'll be wiring those? It may be different since you have the rocker switch. We have the touchpad and while it's great, we haven't found a place we really love having it. I was considering wiring up an auxiliary set of controls to a couple of blank buttons where you did your rocker switch, and then putting the touchpad in the armrest. I figured that would give us our every day functions right there and the touchpad close by if we wanted manual control. I know accuair does sell an auxiliary harness but I haven't seen how it's wired up yet.

But seriously, very cool build and I'm looking forward to more updates

madone_si
05-12-2014, 08:17 PM
outstanding work on Audi Avant man.

AKO
05-12-2014, 09:27 PM
Thanks man! I wish I could go, but it doesn't look like my schedule will allow it. Where's a good way to find out about the Euro meets in the PNW?

Bummer! Well definitely try and make it over the mountains to some local meets. Check the Northwest regional section

mec
05-12-2014, 09:36 PM
You should get some seat covers for your car because the girls are gonna be leaving madddddd snail trails on your seats.

CLEANA3
05-13-2014, 08:07 AM
Looking dope

#Avantbuild
05-13-2014, 08:10 AM
Not gonna lie it would have been really cool if you could have wired in some old allroad buttons for your ride height adjustment!

I hadn't even thought of that, it would be super clean though. Great idea!

#Avantbuild
05-13-2014, 08:20 AM
Very cool build. We have an extremely similar trunk layout as yours except confined in the stock spare tire well. Oddly I don't have any good pictures of it, but here was one of our initial test fits with almost everything connected

I ended up extending the VU4 harness in a similar fashion to you, and mounted the ECU under the factory floor behind the rear seats

We're still in the process of getting everything cleaned up but it's been running and functional for a couple months and we're very happy with it so far. I'm sure you will be too.


I do have a couple questions though, specifically in regards to your paddle shifters. I'm curious how you'll be wiring those? It may be different since you have the rocker switch. We have the touchpad and while it's great, we haven't found a place we really love having it. I was considering wiring up an auxiliary set of controls to a couple of blank buttons where you did your rocker switch, and then putting the touchpad in the armrest. I figured that would give us our every day functions right there and the touchpad close by if we wanted manual control. I know accuair does sell an auxiliary harness but I haven't seen how it's wired up yet.

But seriously, very cool build and I'm looking forward to more updates

Thats super cool man! I'm glad to see some more hidden systems with full trunk access. [up] Do you have two pressure sensors in your forward tank?? As far as the wiring goes for the paddle shifters, I have not completed that project yet. I'm in the middle of doing the E-level sensors ATM, and will get there eventually. What I've decided to do is have the rocker switch for daily functions but have the iLevel module so I still have all the touchpad functions on my iPhone whenever I need it. It's a slick system that is almost instantaneous in response even over wifi. It's impressive. So, if you wanted to keep touchpad capabilities, you could switch over to the rocker switch harness, then buy the iLevel as well, sell your touchpad, and be out a couple hundred bucks I'd imagine. Accuair just released the Android platform app yesterday I believe, so that's not a barrier anymore for some people. [up]

datwagn
05-13-2014, 08:40 AM
I will say one thing... Learn how to do multiple quotes in one response haha rather than 10 seperate posts.

#Avantbuild
05-13-2014, 08:51 AM
I will say one thing... Learn how to do multiple quotes in one response haha rather than 10 seperate posts.

Literally just read about that in the forums guidelines. My bad guys lol, I've never done this before.

I'll fix that now. [up]


Sent from my iPhone using Tapatalk

A-BlacK_MambA-4
05-13-2014, 09:40 AM
With a build thread like this we'll let it slide man lol Killer job all around. I don't think I would have to balls or patience to do half of this. BTW I looked into those GF6s for my B7, but caught a killer deal on some RH ZW4s. Love the concavity of them lol [up]

AKO
05-13-2014, 11:44 AM
Good deal, I'll check that out. I'm hoping to get out there and show the build in person. [:D]

Look forward to seeing it sometime hopefully then. There's usually a small GTG every week here on the eastside! What do you do if you dont mind me asking? Noticed all the awesome tools haha [:D]

tankdeer
05-13-2014, 11:58 AM
Thats super cool man! I'm glad to see some more hidden systems with full trunk access. [up] Do you have two pressure sensors in your forward tank?? As far as the wiring goes for the paddle shifters, I have not completed that project yet. I'm in the middle of doing the E-level sensors ATM, and will get there eventually. What I've decided to do is have the rocker switch for daily functions but have the iLevel module so I still have all the touchpad functions on my iPhone whenever I need it. It's a slick system that is almost instantaneous in response even over wifi. It's impressive. So, if you wanted to keep touchpad capabilities, you could switch over to the rocker switch harness, then buy the iLevel as well, sell your touchpad, and be out a couple hundred bucks I'd imagine. Accuair just released the Android platform app yesterday I believe, so that's not a barrier anymore for some people. [up]

Yeah. Retaining all of the OEM cargo space was our number one priority. It is after all a huge reason why avants are so awesome, ha ha. It will be a slowly evolving project as we eventually make it look pretty as well, including painting the tanks, hardlines, etc. I've already started cleaning up and tucking as much wiring as is practical. Eventually there will be an auxiliary air line with some basic tools hidden in the driver's side trunk compartment (where you have your ECU & evap).

As for the pressure sensors, yes there are two. We have a Zaetech Digigauge hidden in our glovebox which monitors the tank pressure as well as all 4 bags individually. It's really a slick setup (you can see the other 4 sensors sticking out of the VU4) and a nice add on in addition to the e-level. I did see the release of the android version of i-level which is great, and something we'll consider. I really dig the idea somebody mentioned about the allroad buttons. I may have to look into that.

Cheers

#Avantbuild
05-15-2014, 08:20 AM
I will say one thing... Learn how to do multiple quotes in one response haha rather than 10 seperate posts.

Thanks for the feedback lol, I figured it out now. [up]


With a build thread like this we'll let it slide man lol Killer job all around. I don't think I would have to balls or patience to do half of this. BTW I looked into those GF6s for my B7, but caught a killer deal on some RH ZW4s. Love the concavity of them lol [up]

Haha! Thanks man, I'm excited to share some of the steps I took. Ooooh I do like ZW4's, they kinda remind me of the Keskin KT-1's I ran on my R32 a couple years back. Stoked for you!!


Look forward to seeing it sometime hopefully then. There's usually a small GTG every week here on the eastside! What do you do if you dont mind me asking? Noticed all the awesome tools haha [:D]

Yeah for sure dude! I'm excited too. Lol, well I'm still a full-time student at Walla Walla University, but I do freelance photography for weddings and commercial work. You can check out my site if you'd like: www.kurtislamberton.com
As for the tools.. well, as an automotive student we get 40-50% off all Snap-On, Matco, and Cornwell tools. [up]


Yeah. Retaining all of the OEM cargo space was our number one priority. It is after all a huge reason why avants are so awesome, ha ha. It will be a slowly evolving project as we eventually make it look pretty as well, including painting the tanks, hardlines, etc. I've already started cleaning up and tucking as much wiring as is practical. Eventually there will be an auxiliary air line with some basic tools hidden in the driver's side trunk compartment (where you have your ECU & evap).

As for the pressure sensors, yes there are two. We have a Zaetech Digigauge hidden in our glovebox which monitors the tank pressure as well as all 4 bags individually. It's really a slick setup (you can see the other 4 sensors sticking out of the VU4) and a nice add on in addition to the e-level. I did see the release of the android version of i-level which is great, and something we'll consider. I really dig the idea somebody mentioned about the allroad buttons. I may have to look into that.

Cheers

That's sick man!! I have the fittings for an auxiliary air line too, just haven't put it in yet. That's awesome! I think it'd be sick to just pull up next to someone with a flat tire, pop the trunk, pull out an air line and impact wrench and go to town. lol
Ahhh, I see about the sensors. What advantages does that give you - as far as having individual pressure readings for the bags? Is it just to monitor if you have leaks when your system is off?

tankdeer
05-15-2014, 08:48 AM
Ahhh, I see about the sensors. What advantages does that give you - as far as having individual pressure readings for the bags? Is it just to monitor if you have leaks when your system is off?

It was super helpful the first week or two when we were still fixing all the little leaks and stuff. We could easily see if one bag was significantly lower or if the tank pressure dropped drastically overnight. Now that all the little issues are ironed out it's helpful that we have a general idea of what the pressures should be at ride height, so if something is off we can easily see. Definitely not something that is necessary especially with e-level but I'm glad we have one extra way to monitor everything.

joker_2.0
05-15-2014, 02:31 PM
awesome build man, love seing more bagged avants.

What made you decide to cut out the spare tire well though?
Like Tankdeers, Thats how i have my trunk set up aswell.

Its funny, my build was almost the same reaseon, loved my old jetta but needed a wagon for work/family and wanted all the management hidden.

chekc out my build thread.

http://www.audizine.com/forum/showthread.php/481516-My-Avant-built

#Avantbuild
05-21-2014, 08:26 AM
Hey everybody, sorry for the delay. A good friend of mine got married in Yosemite, so I was down there for a couple days. BUT, it's time for an update!

BAG INSTALL: Part 1

Now, back when I started this build, Accuair still was working on the B7 A4 bag setup. I really wanted to go with Accuair stuff, and at the time they only had the B8 sport kit for production, so after a few phone calls with Drew from DorbritzDesigns he assured me that the B7 and B8 suspension mounts were practically the same, and that there shouldn't be too much modification necessary. I'd love to say that was the case, but it really wasn't.. I'll explain more in detail later.

For now, I want to show you exactly what kit I have.

http://www.accuair.com/vehiclekitproducts/accuair-sport-air-suspension-audi-b8
http://www.tagmotorsports.com/accuair-audi-b8-full-air-solution

If you look at the Tag Motorsports site you can see the image gallery that shows that the front bags slip over the front struts and sit nicely on the ridge indentation on the shock. Unfortunately the B7 ones aren't the same diameter, so in the image below you can see the in order for the bags to sit right I needed to keep the stock spring perch installed.


So when I test fitted the Ground Force GF6 wheels earlier the stock shocks didn't allow me to go down as low as I wanted, so I got the aggressive lowering Koni shock, MFG# 8240-1185SPORT. So here I've slipped the B8 sport air spring over the front struts.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-2.jpg.html)

Here I'm sitting on the alignment rack with my stock suspension and wheels/tires on.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-3.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-3.jpg.html)

Here I'm stoked about installing the new bags!

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-5.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-5.jpg.html)

Excitement didn't last too long, cause it was a long process to figure out what needed to be done to retrofit the B8 to the B7.

Pulled the front strut, upper control arm, and strut mount out.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-6.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-6.jpg.html)

Pulled the upper control arms off so I could fit it in the spring compressor.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-7.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-7.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-8.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-8.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-9.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-9.jpg.html)

I knew that I wanted to be able adjust my camber because my target ride height was going to be lower than stock, and I wanted to get a proper alignment so I don't have aggressive tire wear. I bought SPC adjustable control arms that allow me to have multiple degrees of camber and caster adjustment. However, they're slightly larger than the stock arms, and thus the upper strut mount must be modified to allow your wheels to tuck up into the fender. You can see the black sharpie showing where you need to grind down.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-11.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-11.jpg.html)

Here is it after grinding. I used carbide aluminum bits with a 1/4" die grinder to do this.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-12.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-12.jpg.html)

Side view to show how this allows the arms to go up higher.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-13.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-13.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-18.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-18.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-19.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-19.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-16.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-16.jpg.html)

Here's the ground down spring perch for the air fitting on the front bag.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-54.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-54.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-55.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-55.jpg.html)

Strut assembly fully assembled.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-56.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-56.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-57.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-57.jpg.html)

Installation was simple, and exactly the same way as installing an OEM spring/strut assembly. Keep in mind that if you are putting in adjustable upper control arms, make sure they're installed the correct orientation, also, to reduce the amount of time you need to align the vehicle, twist and turn the arms to approximately the same length as the stock arms before bolting into the strut mount assembly. [up]

Here you can see that the bag has started to collapse because it's not hooked up to the airline yet.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-14.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-14.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-15.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-15.jpg.html)

Next comes the rear.

I was told that the rear was also very similar to the B8, and it should be pretty much a direct bolt on. Well.. Lets take a look at that. Here is a picture looking at the underside of the B8 platform. You can see that the lower control arm that the bag assembly sits on is fairly small, in fact, the edge of the bag is extended past the edge of the lower control arm.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Screenshot2014-05-21080923.png (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Screenshot2014-05-21080923.png.html)

Here is the B7 rear lower control arm. It's very different, and underneath that spring perch is a cone shape protruding upwards to keep the spring from sliding that is approximately 1.5" tall.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/aa0108_img_6457.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/aa0108_img_6457.jpg.html)

Here I'm putting together the rear bags as per Accuair's instructions on top of my tool box.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-20.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-20.jpg.html)

You need to remove the fender liners in the rear to get to the upper strut tower mount.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-21.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-21.jpg.html)

There's a lot of methods to get the spring out, and I don't trust those death stick spring compressors, so I unbolted the upper shock mount, removed the sway bar link bolt, and loosened all (4) 19mm frame bolts that hold the upper and lower control arms to the frame. Don't remove these completely, they're much more difficult to get back in if you unthread the entire bolt, but if you leave 4-5 threads you'll be able to manipulate the lower control arm enough to get the spring out. I used a pry bar, and it was a piece of cake.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-23.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-23.jpg.html)

Here's the spring perch that I was talking about. This is a problem, because the B8 sport kit rear bags require a flat surface and a circle cutout for the mounting plate.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-24.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-24.jpg.html)

So here I've taken m cutoff wheel and taken that perch off.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-25.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-25.jpg.html)

Here I've marked out the circle I needed to cutout for the mounting plate. ***Note: this is on the driver side rear***

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-44.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-44.jpg.html)

This is what it looks like when the mounting plate is installed.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-29.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-29.jpg.html)

#Avantbuild
05-21-2014, 08:27 AM
BAG INSTALL: Part 2

A closer look of the mounting plate.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-28.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-28.jpg.html)

Accuair provides a template for drilling the holes for the upper mount on the rear bag assembly. The pictures were a little confusing, so hopefully this clears it up a little bit, but basically the camera is pointed up towards the roof and I'm holding the paper guide upside down underneath the upper spring mount on the rear upper control arm. ***Note: the drive axle is UNDERNEATH***

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-26.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-26.jpg.html)

Now, here's where you need to modify a little bit to make it work. If you use the mounting holes from the template then the bag itself will sit too close to the drive axle and will rub when fully pressurized. You don't want this. So, what I ended up doing is shifting the template holes you drill 3/4" forward, towards the front of the car. That gives you the extra room needed to be able to safely travel at ride height (3) without rubbing your bag against the axles.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-27.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-27.jpg.html)

Here's the rear bag installed.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-30.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-30.jpg.html)

Upper view of the drivers side rear.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-51.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-51.jpg.html)

Here you can see the front Koni's installed with the bags.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-62.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-62.jpg.html)

Here I've dropped the rear, but I had a slight issue because my bump stop kept me from going low enough! .... I'll fix that. [drool]

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-59.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-59.jpg.html)

Here I've cut my bump stop.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-61.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-61.jpg.html)

That's better. [hail]

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-64.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-64.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-65.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-65.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-67.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-67.jpg.html)

Before I put the wheels back on I knew that since I hadn't rolled the fenders yet I'd be hitting the fender, or at least very close to it, so I used the 18mm eccentric bolts on both sides to give myself the highest degree of negative camber so I could lower it.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-39.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-39.jpg.html)

Now, at this point I haven't aligned it yet, so everything is out of whack, but the system was functioning! NOTE: I have NOT installed the e-level ride height sensors yet, so I was manually controlling the bag pressure with the iLevel app on my iPhone. The Rocker switch does not function until it's paired with the ride height sensors.

Here's a look of the Avant on the ground. [:D] [drool]

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-66.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bags/Avantbuild_Bags-66.jpg.html)

#Avantbuild
05-21-2014, 08:27 AM
BUMPER: Part 1

Alright.. I've been keeping this under wraps, except for all the propaganda via instagram lol, mostly because it's still an unfinished project, but it time I share what I'm up too. Everybody knows that the B7 A4 non s-line has the least aggressive looking front bumper of all time; perhaps the Toyota Prius has more interesting lines going on there, JK. [>_<] But seriously, when parked next to the RS4, or the B8 S5, S4, or even the A4, the B7 just has little happening for itself. I do however, LOVE the B7 headlights. I think they flow much better with the fenders, but of course this is personal opinion, so don't try to tell me I'm wrong. I will respect your opinion, and congratulate you on yours, but I have mine and this is my project, so take into account that my comments and statements are slightly skewed to appease my point of view. [:D]

I ran across an amazing build thread on www.edition38.com by a UK guy, Matt, and his Phantom Black B7 A4 S-Line build. User name: felondnb
Here's a link to his build thread: http://www.edition38.com/forums/index.php?showtopic=262923

Matt, you have inspired me, and I don't claim any of my doing as original work, although our processes are slightly different. I applaud your ingenuity, and hope my attempt comes out as good as yours did. [hail]

So, with the inspiration of Matt's incredible build I am doing a facelift of the B7. I am combining my B7 A4 non s-line front bumper with a B8 A4 s-line, to create the harmony of beautiful headlights, fender lines, with the aggressive lower section of the B8. [up]

I'm going to throw a ton of progress pictures at you, but it is not finished yet. I got started on this part of the project while waiting for air ride parts, so when those showed up I abandoned the bumper, for the meantime, and started the air build.

I spent many hours online sourcing a good quality B8 A4 s-line bumper, and eventually found one via eBay that cost me $315 shipped from Minnesota. It arrived in good condition, but it was a "repaired" bumper. But why should I care lol, I was about to cut it up always!

Here's the bumper sitting on top of my A4, back in February.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-1.jpg.html)

Contemplating the cut lines.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-2.jpg.html)

I used vinyl tape to help guide my cuts . I placed the B8 A4 bumper on top of my stock one to help me decide what parts of each needed to go in order to mate the two together in the cleaned possible way.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-3.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-3.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-5.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-5.jpg.html)

Close up of the B7 bumper on the fog light grills.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-6.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-6.jpg.html)

Fornt view of the B7.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-7.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-7.jpg.html)

B8 taped up for cutting.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-8.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-8.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-9.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-9.jpg.html)

The cutting has begun!

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-10.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-10.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-11.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-11.jpg.html)

Here I'm using my dremel to cut through my B7 bumper. ***Note: I removed all the components on the backside of the bumper prior to cutting, i.e. windshield washer components, fog lights, etc.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-12.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-12.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-13.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-13.jpg.html)

Here is the two sitting next to each other, after the B7 fog light grills have been cut out for the B8 clearance.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-14.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-14.jpg.html)

Look how much wider the B8 is!!

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-15.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-15.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-16.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-16.jpg.html)

Well.. there's no gong back now. lol B7 bumper is officially screwed. [:D]

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-17.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-17.jpg.html)

Views of how well they match up.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-18.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-18.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-19.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-19.jpg.html)

Here, on the inside of the blue vinyl tape (side closest to the bench) I'm cutting to let the B8 sit flush against the B7 bumper.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-20.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-20.jpg.html)

Using zippies to help visualize what it could look like mated together.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-21.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-21.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-22.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-22.jpg.html)

Because the B8 is slightly wider, you can see stress in the lower grill area.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-23.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-23.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-24.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-24.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-25.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-25.jpg.html)

Here I've shaved a bit more off the B8, and made a relief stress cut in the lower grill. Starting to fit a lot better!

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-26.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-26.jpg.html)

I used a combination got screws and rivets to help hold the two bumpers together before I mated them using SEM body products.

#Avantbuild
05-21-2014, 08:28 AM
BUMPER: Part 2


http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-27.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-27.jpg.html)

Here you can see that the lower side of the B8 grill is sitting just below the lower side of the B7 grill. This allowed for the best body lines with the wider bumper mated to the B7 one.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-28.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-28.jpg.html)

Impossible to find B8 s-line fog grills..... ended up paying top $$ from ECS tuning to get them. Unfortunately the B8 fog lights I purchased for them don't fit and I can't return them... bummer deal guys!

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-29.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-29.jpg.html)

Backed up view of the conversion.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-30.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-30.jpg.html)

I think it looks pretty mean!

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-31.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-31.jpg.html)

Here's the stuff I got to mate the two bumpers together. SEM Quickset50 is killer stuff, but the claimed 3 min set time is crap, it literally hardened in 30-60 seconds. So if you use this stuff, do it QUICK!! You go through tips super quick too.. so make sure you got like 10 of them on you before you start.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-33.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-33.jpg.html)

The "red" bumper is the B8, and the black is the B7. Here I've sanded down the edges to either make it more flat, or give the Quickset50 some grip to hold when it sets.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-34.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-34.jpg.html)

Here I'm laying down the meshing structural material for the Quickset50 to adhere too.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-35.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-35.jpg.html)

I did this process to both sides, front and back. You can see the gloss surface of the Quickset50.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-36.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-36.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-37.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-37.jpg.html)

Sanding has begun!

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-38.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-38.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-39.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-39.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-40.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-40.jpg.html)

Mmmm, yes.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-41.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-41.jpg.html)

Oooh, look at that fender gap!! [=(] [headbang] [wrench]

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-42.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-42.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-43.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-43.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-44.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-44.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-45.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-45.jpg.html)

Here's the gap from the B8 to the B7 lower area where it meets up with the wheel well.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-46.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-46.jpg.html)

A professor has some extra polyurethane blocks they use for CNC demos and gave me about a 1x1' block to play with.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-47.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-47.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-48.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-48.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-49.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-49.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-50.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-50.jpg.html)

Using the last bit of the Quickset50 to adhere to polyurethane to the bumper. Keep in mind that each Quickset50 tube is $50! Ouch.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-51.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-51.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-52.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-52.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-53.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-53.jpg.html)

#Avantbuild
05-21-2014, 08:28 AM
Unfortunately, this is as far as I've come. But I have plans to finish this AS SOON as I can finish up the paddle shifter air ride problems I'm having. (I've been working on that Thursday-Friday)

However, I did snap a few pictures today, as of 30 min ago to show you what it looks like dropped. [up]

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/EF5C51A0-55CB-4BB3-8479-96D2F7647637.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/EF5C51A0-55CB-4BB3-8479-96D2F7647637.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/251E5D1D-B127-4929-84D3-38720EFEFDA6.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/251E5D1D-B127-4929-84D3-38720EFEFDA6.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/8169D029-DB9B-43C6-8685-5D05E4B60D17.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/8169D029-DB9B-43C6-8685-5D05E4B60D17.jpg.html)

I'm a fan. What do you guys think?

#Avantbuild
05-21-2014, 08:29 AM
Reserved......

#Avantbuild
05-21-2014, 08:29 AM
Reserved.......

#Avantbuild
05-21-2014, 08:30 AM
Reserved........

#Avantbuild
05-21-2014, 08:30 AM
Reserved.........

Audi_509
05-21-2014, 09:19 AM
Everything looks top notch. Great job.

How about I buy a kit and you help me with the install. [:D]

B7AUDITURBO
05-21-2014, 12:26 PM
That rub thoeeeeee amazing work
[az]

Kemiksiz
05-21-2014, 12:34 PM
A lot of effort, I am fully supporting that kind of entrepreneurship :))

Krusty
05-21-2014, 10:53 PM
This looks fucking insane! Congrats on a job well done. How about some vids of the ride at work!?

jaycurn
05-22-2014, 08:21 AM
WOW, EPIC!!! Subscribed!

jnm
05-22-2014, 08:27 AM
[drool][up] Looking great so far.

Thomas Chagrin
05-22-2014, 10:29 AM
All of it is amazing, man. Wheels are fantastic! I looked on the MRR website and those aren't listed under Audi fitment. Did they do a custom bolt pattern for you? Are they soon to be released? They look perfect on your Avant...

Capt. Obvious
05-22-2014, 11:28 AM
It's a little late now, but if you would have mounted the rear bags upside down, it would have saved you a lot of work, since the upper mounts would have cleared the hump in the lower control arm, and would have provided the spacing needed to clear the axle.

Geoffafa
05-22-2014, 11:44 AM
It's a little late now, but if you would have mounted the rear bags upside down, it would have saved you a lot of work, since the upper mounts would have cleared the hump in the lower control arm, and would have provided the spacing needed to clear the axle.

agree'd, also i think it would rub less on the lower arm when airing out, not sure if it does touch, but just another reason for my opinion.

joker_2.0
05-22-2014, 01:53 PM
I'd be more worried about the bag rubbing on the axle, ask me how i know :(

Operator
05-23-2014, 07:24 AM
A little late to the party, but the quality of work being put in is tops!!!!

Looking at the install pics:

http://i743.photobucket.com/albums/xx73/eurosonik/GIFs/doc51314319_136630637_zps56d572f4.gif

4rings5stars
05-24-2014, 12:56 PM
Wowsers

#Avantbuild
05-27-2014, 08:06 AM
Everything looks top notch. Great job.

Cheer man!

How about I buy a kit and you help me with the install. [:D]

Haha! Absolutely! [:D]


That rub thoeeeeee amazing work
[az]

[>_<] Thanks homie


A lot of effort, I am fully supporting that kind of entrepreneurship :))

Thank you, the support is so much appreciated.


This looks fucking insane! Congrats on a job well done. How about some vids of the ride at work!?

Thank you! That will come soon, got a couple more little ends to tie up, then the big reveal will happen. [up]


WOW, EPIC!!! Subscribed!

[up] [up] :)


[drool][up] Looking great so far.

[>_<] Thanks much


All of it is amazing, man. Wheels are fantastic! I looked on the MRR website and those aren't listed under Audi fitment. Did they do a custom bolt pattern for you? Are they soon to be released? They look perfect on your Avant...

Cheers sir, that's correct, they aren't listed because the offset is so aggressive. I did all my own measuring and calculations to determine where the wheels would sit in the fender arches and had to agree with MRR's supplier (A-Spec Wheels based in CA) that I was willing to purchase even though there was no possibility to return them. But alas, they DO fit! haha (Take note, the et +15 I have mounted in the rear WILL NOT FIT the front from the stock brakes. The et +25 I have mounted in the rear clear the front brake calipers by 3/8", which is probably not enough for those of you with BBK's.. unless the rotors have a larger diameter and the calipers are mounted farther to the outside where the deep concave spokes will easily clear. [up]

#Avantbuild
05-27-2014, 08:17 AM
It's a little late now, but if you would have mounted the rear bags upside down, it would have saved you a lot of work, since the upper mounts would have cleared the hump in the lower control arm, and would have provided the spacing needed to clear the axle.

I believe that is technically true. Good idea! The only reservation I have about that, and I can't back it up because I didn't try it, is that if you flipped that upside down, removed the top plate so there's a spacing for the hump in the lower control arm to sit it, you don't really have anything to bolt the bag down. The sidewalls of the spacers are pretty thin, so I'm not sure where you would secure the lower mount to the lower control arm. However, it's worth exploring. Great suggestion!


agree'd, also i think it would rub less on the lower arm when airing out, not sure if it does touch, but just another reason for my opinion.

I agree with that statement as well. The O.D. is actually slightly smaller when aired out compared to max pressure (the bag seems to implode on itself) so it doesn't rub when aired out, or under any circumstance except for full extension. So, instead of setting my level height 3 at complete full pressure, I've kept it from going up the last 1/2" and that's enough to keep it from rubbing, and any bump or flex in the suspension upward just increases the gap between the bag and the axle, so I THINK I'm good. We'll see. ;) I could come back here halfway through a road trip and report otherwise. [>_<]


I'd be more worried about the bag rubbing on the axle, ask me how i know :(

Story! Sorry man, that doesn't sound fun.


A little late to the party, but the quality of work being put in is tops!!!!

Looking at the install pics:

http://i743.photobucket.com/albums/xx73/eurosonik/GIFs/doc51314319_136630637_zps56d572f4.gif

Haha! Cheers homie [up] [up]


Wowsers

[>_<] [up]

Audi_509
05-27-2014, 09:23 PM
Man, don't temp me to get the CC. [:D]

Any new updates. Will you be finish before you graduate?

k909068
05-27-2014, 11:43 PM
Amazing work you did here, can't remember what was I doing when 23, lol

Geoffafa
05-28-2014, 09:59 AM
Dont know if anyone has noticed the b8 bumper conversion pics on page 2... but fucking wow! thats serious man i respect the amount of work on the bumper alone.

Audi_509
05-28-2014, 01:01 PM
^ Thanks for pointing that out. I forgot that he reserved a few post for updates.
A lot of stuff he is tackling. This a very impressive build.

#Avantbuild
05-29-2014, 08:45 AM
Amazing work you did here, can't remember what was I doing when 23, lol

Thanks man, I appreciate it!


Dont know if anyone has noticed the b8 bumper conversion pics on page 2... but fucking wow! thats serious man i respect the amount of work on the bumper alone.

Thank you! It's still in process, but I'm really excited about the potential results. [up]


^ Thanks for pointing that out. I forgot that he reserved a few post for updates.
A lot of stuff he is tackling. This a very impressive build.


Man, don't temp me to get the CC. [:D]

Any new updates. Will you be finish before you graduate?

Thanks man, I appreciate it. I'm currently working out a wiring schematic for the paddle shifters that won't fry the clock spring and/or steering column control unit circuit board. It's taking a little longer than expected, but then again I was told it wasn't possible, so I'm not too distraught yet. I present my senior project on June 14th, at 9:00 am so that is when I need it working by. Luckily for me, in my senior project proposal I only had the Airride conversion and the paddle shifter mod in there. So even if I can't get the trunk polished up, the bumper completed, the vinyl wrap done, etc I am still fulfilling the requirements as long as I get the paddle shifters working. [up]

tankdeer
05-29-2014, 08:59 AM
I present my senior project on June 14th, at 9:00 am
Shame. Sounds like you won't be at Leavenworth this year then?

leftovers
05-29-2014, 09:56 AM
I understand the "reserved comments" concept, but I think it makes it hard for us to know when there are new updates. And the replies people are making aren't going to line up with your post very well chronologically.

That being said....you put a ton of time into that bumper. I think it looks great so far. I just don't think I could justify the amount of work. You should keep it up though. The end product will be worth it for you.

Capt. Obvious
05-29-2014, 01:21 PM
Please don't do the "reserved" spots for updates. It makes it too hard to tell when you've actually made updates. That's why no one else does it.

#Avantbuild
05-30-2014, 10:30 PM
Shame. Sounds like you won't be at Leavenworth this year then?

[=(] I'm afraid so....


I understand the "reserved comments" concept, but I think it makes it hard for us to know when there are new updates. And the replies people are making aren't going to line up with your post very well chronologically.

That being said....you put a ton of time into that bumper. I think it looks great so far. I just don't think I could justify the amount of work. You should keep it up though. The end product will be worth it for you.


Please don't do the "reserved" spots for updates. It makes it too hard to tell when you've actually made updates. That's why no one else does it.

You're both right, sorry guys. I'm definitely still getting the hang of this. I'll make sure to update in a new section so it's clear I've added things. Thanks for the feedback. [up]

#Avantbuild
05-30-2014, 10:35 PM
Hey everyone, just wanted to share an update. I decided, after finishing some pretty exciting but "secret" stuff up today, that it was time for an "official" test drive. So I took the wagon to Kennewick, WA about 45 min away from Walla Walla. I stopped by a shipping yard on the way back to grab a few quick shots. I'm very pleased with the results! In fact, I'm extremely happy. I put the front bumper conversion on here so you could see the progress.. which isn't much, but maybe you can just "imagine" what it it'll be like when it's complete haha.

I'm going to be releasing a video soon to show you what I've been up too, so stay tuned!! Don't forget to follow my instagram too for project updates. Username: kurtislamberton or the hashtag #avantbuild.

Happy Friday everybody!

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Photo%20Ops/Avantbuild_Sunset-TriCities2014-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Photo%20Ops/Avantbuild_Sunset-TriCities2014-1.jpg.html)

#Avantbuild
05-31-2014, 12:33 AM
Alright, so the moment that I've been waiting for is here... I'm very pleased to announce that I have completed the paddle shifter mod and it is working beautifully, paired with the Accuair e-Level control system. I've made a very short promo vid for you to watch to see it work. A lot of experimental design and work went into this part of the project and it involved modifying a circuit board plus many other things. I am excited to share what nobody thought I would be able to do.. so without any further adieu, please, enjoy.



https://www.youtube.com/watch?v=M5beTteQ1bw

mec
05-31-2014, 12:36 AM
hmm haven't heard emancipator in a while, good choice in music!

Audi_509
05-31-2014, 01:11 AM
Sweet! It's so cool that you got the paddles to work with your air ride.

http://www.cool-smileys.com/images/65.gif (http://cool-smileys.com//smiley-clapping-hands)

Audi_509
05-31-2014, 01:17 AM
delete

leftovers
05-31-2014, 05:36 AM
The promo is cool. Nice job on the paddle shifters.

4rings5stars
05-31-2014, 05:42 AM
Very cool and inventive.

What's your major that the avant is part of your senior project?

Salt n Peppa
05-31-2014, 05:48 AM
What the hell do the poor kids do for their project lol dang

Sent from Thunderpants Headquarters

xander3zero
05-31-2014, 05:48 AM
Alright, so the moment that I've been waiting for is here... I'm very pleased to announce that I have completed the paddle shifter mod and it is working beautifully, paired with the Accuair e-Level control system. I've made a very short promo vid for you to watch to see it work. A lot of experimental design and work went into this part of the project and it involved modifying a circuit board plus many other things. I am excited to share what nobody thought I would be able to do.. so without any further adieu, please, enjoy.



https://www.youtube.com/watch?v=M5beTteQ1bw

Fresh

Sent from my Nexus 7 using Tapatalk

xander3zero
05-31-2014, 05:49 AM
What the hell do the poor kids do for their project lol dang

Sent from Thunderpants Headquarters

Lol!

Sent from my Nexus 7 using Tapatalk

drumnjuny
05-31-2014, 06:32 AM
wow just caught up. great build!!!

Yogie
05-31-2014, 01:41 PM
Legit. Following you on IG.

A4 Effort
05-31-2014, 06:46 PM
Outstanding work; can't wait to see the finished project [up]

Solarsuplex
06-01-2014, 10:32 AM
My god this makes me want to go to town on my bumper with a b8. Looks incredible. Thought about getting an rs4 grille? Awesome job again.

Also, feel free to do a reserved post thing, just post the actual update in the thread as it happens.

CLEANA3
06-01-2014, 01:02 PM
pure sex . looking good

#Avantbuild
06-02-2014, 01:27 PM
hmm haven't heard emancipator in a while, good choice in music!

I had never heard them before! It's about time I suppose. lol


Sweet! It's so cool that you got the paddles to work with your air ride.

http://www.cool-smileys.com/images/65.gif (http://cool-smileys.com//smiley-clapping-hands)

Thanks man!! I'm thrilled it works so well. Now I just need Accuair to hire me. [:D]


The promo is cool. Nice job on the paddle shifters.

Thank you man, I appreciate it.


Very cool and inventive.

What's your major that the avant is part of your senior project?

Thank you sir! I'm a Automotive Management Major. Basically a 4-year degree in automotive service plus almost an equivalent of a business degree. [up]


What the hell do the poor kids do for their project lol dang

It's entirely up to the student really. A lot of people don't necessarily have the opportunity to do a big budget build, so the University helps them with a project. i.e. a couple years ago a student designed and built our entire alignment rack and the University paid for and/or materials got donated as it was a direct advancement in the Automotive program.


wow just caught up. great build!!!

[up] Thanks homie!! [up]


Legit. Following you on IG.

I saw that! Woot [>_<]


Outstanding work; can't wait to see the finished project [up]

You and me both! Thanks for taking a look!


My god this makes me want to go to town on my bumper with a b8. Looks incredible. Thought about getting an rs4 grille? Awesome job again.
Also, feel free to do a reserved post thing, just post the actual update in the thread as it happens.

Hey dude! Thank you. I've thought about the RS4 grille, but I've never liked the look of the plate fillers. I envy the RS5 front end so much that I decided I wanted to do a stealthy front grille that is just honeycomb from an RS6 bumper. So, in the end, this frankenstein v.2 bumper will be made up of (1) B7 A4 non s-line bumper cover, (1) B8 A4 s-line bumper cover, and (1) badge less B7 RS6 grill. Boom! [up]


pure sex . looking good

Thank you! [drool]

Capt. Obvious
06-02-2014, 01:55 PM
That B8 front bumper is a perfect match for your car. It's going to look amazing once completed.

txtaco1
06-03-2014, 05:48 AM
Man, that is sick!!! I must have spent 3 hours reading this and looking at your pics last night. Between your writing, photography, and your ability to work on things I think you on the right track. Like one other member said above "I can't remember what I was doing at 23"!

Keep the updates coming and good luck on your final grade... It should be an A++++

Thanks,
Jason

#Avantbuild
06-06-2014, 02:49 PM
http://img.tapatalk.com/d/14/06/07/eparame4.jpg

Beautiful day for a little bumper work! Happy Friday everybody. In case you didn't see it, Accuair reposted my short video on their Instagram. Pretty excited about that!


Sent from my iPhone using Tapatalk

BigFat
06-06-2014, 03:14 PM
Amazing man, great work!

#Avantbuild
06-12-2014, 12:01 AM
Hey everyone, I've been super busy with finishing up finals and everything else required to graduate this Sunday so I haven't made too much progress on the car. However, tomorrow AM I'm presenting my senior project to the Board of Technology so I did a little wash and wax to take a few final photos for my presentation so I figured I'd at least share those.

I'm traveling a little bit after grad, but once I'm back I'm hitting the bumper to get that done and then commence with the vinyl wrap and finish up the hardwood floor in the trunk!

e-Level ride height (3)
http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Photo%20Ops/Avantbuild_Sunset-WWU2014-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Photo%20Ops/Avantbuild_Sunset-WWU2014-1.jpg.html)

e-Level ride height (parked)
http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Photo%20Ops/Avantbuild_Sunset-WWU2014-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Photo%20Ops/Avantbuild_Sunset-WWU2014-2.jpg.html)

(cheesy grin for new fb profile pic lol)
http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Photo%20Ops/Avantbuild_Sunset-WWU2014-3.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Photo%20Ops/Avantbuild_Sunset-WWU2014-3.jpg.html)

Wish me luck tomorrow! Haha, jk. [:D] [up]

LINDW4LL
06-12-2014, 12:43 AM
You did an incredible job on this project. All of the fabrication and integration appears to be top notch. Great work!

Solarsuplex
06-12-2014, 09:02 AM
Where ya traveling? Just drop that bumper off with me and I'll have it pained and put on my car in no time

drumnjuny
06-12-2014, 09:34 AM
man can't wait to see it with that bumper painted. looks amazing; really professional work!

Capt. Obvious
06-12-2014, 10:17 AM
This car is perfect to me. Aggressive and low, but not excessive and still very much usable/practical. Can't wait to see the final product.

However, don't wrap it! The black paint looks awesome. Just give it a solid detail and call it a day!

Solarsuplex
06-12-2014, 12:18 PM
This car is perfect to me. Aggressive and low, but not excessive and still very much usable/practical. Can't wait to see the final product.

However, don't wrap it! The black paint looks awesome. Just give it a solid detail and call it a day!

This is what I was thinking. Wrap is no good. Unless it's matte white and temporary.

Audi_509
06-12-2014, 10:22 PM
Hey everyone, I've been super busy with finishing up finals and everything else required to graduate this Sunday so I haven't made too much progress on the car. However, tomorrow AM I'm presenting my senior project to the Board of Technology so I did a little wash and wax to take a few final photos for my presentation so I figured I'd at least share those.

Wish me luck tomorrow! Haha, jk. [:D] [up]

In-case your Board of Technology do not understand how awesome your work is they need to check out the positive comments in this thread. Then they can followed up with slapping an A+ sticker on your windshield. [:D]
Good luck!

7speed
08-04-2014, 10:43 PM
Great build.I might steal your idea of the tub in the spare tire well. I'm low_enforcement on instagram.

m3fuz
08-05-2014, 05:36 AM
Wow - this is a build thread! Very nice write up and the car looks great. Congrats!

Yogie
08-08-2014, 03:16 AM
Pretty much everything you did is what I wish I had the money to do to my wagon. I am going to attempt the b7 to b8 front. How do you feel about the way the bumpers meet where you cut them? I followed felons conversion, yours, and another ziner who did it and am pretty confident about it. How do the lines flow together where the cut of the old and new meet? All of the ones I've seen from pictures have a harsh angle change near the wheel wells.

#Avantbuild
08-21-2014, 06:12 PM
Great build.I might steal your idea of the tub in the spare tire well. I'm low_enforcement on instagram.

Oh right on, how you doing man? Sweet deal! I want to see progress pics of that!


Wow - this is a build thread! Very nice write up and the car looks great. Congrats!

Thank you sir! I've neglected it the last two months, but hopefully I'll have a few more things to share in the next little bit. Glad you like the car. [up]


Pretty much everything you did is what I wish I had the money to do to my wagon. I am going to attempt the b7 to b8 front. How do you feel about the way the bumpers meet where you cut them? I followed felons conversion, yours, and another ziner who did it and am pretty confident about it. How do the lines flow together where the cut of the old and new meet? All of the ones I've seen from pictures have a harsh angle change near the wheel wells.

[hail] Thanks homie, I appreciate the love. I'll try to take some picture of the bumper finished and close up so you can see the body lines. I thought Felons was really pretty great, but what he did that I didn't like was that he left that hard body line right where the two meet, and to me that wasn't quite OEM enough. I ended up smoothing that completely out so it's flush. It probably took 3x as long because I had to apply filler 15+ times to get it right. It's not "perfect" but it's pretty close, and I've seen some really confused people look at the bumper because its clearly not a bodykit, but it's not a B8 either... :D Which is exactly the reaction I wanted haha. I took it down to Accuair last week in San Luis Obispo and it was really fun to meet their team and talk shop for a couple hours. Reno's S7 is on point, I absolutely love that car. But anyways, I'll try to hook you up with some close up pics of the body line so you can have an idea of what I did. Shoot me a pm and I'll hit you up.

#Avantbuild
08-26-2014, 06:59 PM
Hey all, I apologize for the lack of posting, but with college graduation and a few family trips pre-planned it's not really been a consistent schedule finishing up the front bumper, but I do have some updates for you that I want to share. First of all, I did pass the senior project with flying colors [up] so I'm happy about that! I have my degree in hand so I'm happy about that too. Unfortunately, it's been harder to find a job, so at this point I'm still looking and if nothing comes up I'm potentially thinking about going back to school.. so there's an update about that. If you know any custom shops in the PNW or Cali area looking to hire someone with a great work ethic, un-afraid to do custom work, but has little job experience, let me know! lol


BUMPER: Part 3

So at this point I had most of the blending done and I starting worrying about the front grill. I love the way the RS6 grill looks, especially the badgeless one from Nick's Car Blog. Here's a link to his site and some of the most popular DIY's: http://nickscarblog.com/diy/how-to-fit-an-rs6-grille-on-a-b7-a4-s4-or-rs4-all-mesh-no-filler-plate

So I sourced an aftermarket RS6 all mesh grill from eBay. From the factory an OEM one was >$700 and I knew I was just going to cut it up and repaint it so I went with an aftermarket one which I got out of NY for <$200. Here's the all mesh RS6 grill before I cut it up.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-2-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-2-1.jpg.html)

I used an air saw to slice through the plastic mesh along the grill trim which worked very nicely.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-3-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-3-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-4-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-4-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-5-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-5-1.jpg.html)

I also cut out my OEM grill so I could mesh the badgeless RS6 one into it.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-1-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-1-1.jpg.html)

Here's the all mesh RS6 grill laying on top of my OEM B7 non-sline grill.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-6-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-6-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-7-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-7-1.jpg.html)

Here I've trimmed the bottom of the RS6 grill. It's approximately 2" taller than the OEM B7 non-sline grille frame.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-8-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-8-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-9-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-9-1.jpg.html)

I next took epoxy and used that to adhere the trimmed RS6 grill into my OEM B7 grille frame. I also painted the chrome grille surround flat black to give it a more stealthy look. Here's the whole thing test fitted in the frankenstein B7/B8 front bumper.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-10-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-10-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-11-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-11-1.jpg.html)

I spent hours block sanding the bumper to get it ready for primer. I decided to go with a urethane primer because it's pretty thick, and 2-3 coats was all it took to fill any of the sanding marks and gave me enough material to wet sand it afterwards to prep for base coat.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-14-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-14-1.jpg.html)

Next it was time to fix a mistake I made while rolling the front fenders. I did both driver and passenger side front fenders first without really knowing what I was doing and I don't think I used enough heat. On top of that, there was a little tab that stuck out on the underside of the fender right at the peak of the curve and it make an indentation in the body line that I just couldn't get used too.... so here's the filler applied after we hammered it out and grinded the fender down to base metal.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-12-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-12-1.jpg.html)

Here the primer is going on.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-13-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-13-1.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-15-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-15-1.jpg.html)

At the same time I primed the bumper. Now it's finally starting to look like it's actually a one piece! [up]

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-PrimerPaint-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-PrimerPaint-1.jpg.html)

Here I've masked up the car, ready to shoot the base color on the two fenders, front bumper, and lower front bumper valence.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-PrimerPaint-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-PrimerPaint-2.jpg.html)

In the paint booth.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-PrimerPaint-3.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-PrimerPaint-3.jpg.html)

My good friend Randy helped me shoot the primers, color, and clear.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-PrimerPaint-4.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-PrimerPaint-4.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-PrimerPaint-5.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-PrimerPaint-5.jpg.html)

After letting it bake in the heated booth I loaded her up in the trunk and we went home! I then set it in the sun for two days to cure a little more before I put any stress/flex in it during install.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-PrimerPaint-6.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-PrimerPaint-6.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-PrimerPaint-7.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-PrimerPaint-7.jpg.html)

#Avantbuild
08-26-2014, 08:23 PM
BUMPER: Finished

And here it is! Finished. (Because of the B7 intercoolers the B8 fog lights don't fit, which I knew would happen.. It just means that I'll need to get a FMIC so I can put some fogs in there)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-PrimerPaint-8.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-PrimerPaint-8.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-PrimerPaint-9.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-PrimerPaint-9.jpg.html)

Sitting at ride height.

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-PrimerPaint-10.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-PrimerPaint-10.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Photo%20Ops/Avantbuild_Bumper-1-3.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Photo%20Ops/Avantbuild_Bumper-1-3.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-PrimerPaint-11.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-PrimerPaint-11.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-PrimerPaint-12.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Bumper/Avantbuild_Bumper-PrimerPaint-12.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Photo%20Ops/Avantbuild_BLYC-Summer2014-2.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Photo%20Ops/Avantbuild_BLYC-Summer2014-2.jpg.html)

http://i432.photobucket.com/albums/qq42/kurtislee_1/B7%20Audi%20Avant%20Senior%20Project/Photo%20Ops/Avantbuild_BLYC-Summer2014-1.jpg (http://s432.photobucket.com/user/kurtislee_1/media/B7%20Audi%20Avant%20Senior%20Project/Photo%20Ops/Avantbuild_BLYC-Summer2014-1.jpg.html)

Let me know what you think! I'm extremely happy with it, and I've gotten some curious looks driving by from (it would appear) people that know that bumper and headlight configuration don't come together.. [up] so that's super fun. My goal was to make an OEM looking front bumper that fits a B7 with the B8 flare, and it's REALLY close to achieving that. It's not perfect, but it's pretty close, and I'm very happy with it. [wrench] [a4]

SykoraA4
08-26-2014, 08:26 PM
killer work man. that thing looks stellar.

Kal_el
08-26-2014, 08:49 PM
Awesome journal. You're a talent. The avant came out looking official.

c@@kieMonsta
08-26-2014, 09:22 PM
Wow! I'm so glad that you chose to do this to an avant. Mad respect.

leftovers
08-27-2014, 04:43 AM
I know a lot of work went into that bumper. I love how it turned out. You should be proud. Awesome.

ShadowGLI
08-27-2014, 07:52 AM
I love this thread, love the updates... do you have any extra mesh? maybe try to put some in the bottom most insert? sick either way

Lexxielex
08-28-2014, 03:24 PM
Immaculate!

Lucian189
08-30-2014, 03:08 AM
Super nice finish with that bumper!!
amazing work..
whats the name of the songs you use in your clip?

Shimmy
09-24-2014, 07:14 PM
very nice!!!

SykoraA4
10-02-2014, 05:25 PM
any more pics of this thing?

ultraleggera a4
10-02-2014, 10:26 PM
If you were to start producing this custom bumper, much would you sell them for?

seanentrust
10-08-2014, 10:42 PM
beautiful car! did I see it parked on hawthorne in Portland a few weeks back?

seal66
11-16-2014, 08:43 AM
Damn amazing work!!! Great skill buddy. The whole fit and finish of the car is amazing. I do agree with some on the air ride arrow buttons maybe being something like the old allroad. The fog lights are going to finish the front end off once you get that fmic and can plug them in

ericpaulyoung
11-16-2014, 12:46 PM
Will the chrome rings pop out of your stock grill and fit the aftermarket one? It looks like it is missing in the pictures.

Mister W
11-16-2014, 07:13 PM
Just find that thread
I am speechless [hail] [up]

geebus
11-27-2014, 05:25 PM
I love this car [hail]

drumnjuny
11-27-2014, 07:47 PM
forgot about this for a while.

Jsivadas
12-30-2014, 07:39 AM
Wow great job man! Keep up the good work!![up]

geebus
04-30-2015, 05:07 PM
Moar pics!!!

canadianA4B7
04-30-2015, 05:19 PM
Wow awesome work. I really like that look of the front bumper. Wish there were more scrap yards around my area that actually got newer audi's so I could put something like that together. My non slime body is very plain. But then again I do want to look as stock as possible. But you definitely are pulling off a very stock look with yours. Sent to a friend looking to buy an avant. His first comment was "whatever I buy it has to have that front bumper" told him he's gonna pay a lot more cuz he'll need to buy a newer model yer alltogether. Nice work. Produce a few more of them you've got 2 buyers in Canada if you do!!

Keep up the work great ideas nicely put together

#Avantbuild
06-02-2015, 10:24 AM
Wow awesome work. I really like that look of the front bumper. Wish there were more scrap yards around my area that actually got newer audi's so I could put something like that together. My non slime body is very plain. But then again I do want to look as stock as possible. But you definitely are pulling off a very stock look with yours. Sent to a friend looking to buy an avant. His first comment was "whatever I buy it has to have that front bumper" told him he's gonna pay a lot more cuz he'll need to buy a newer model yer alltogether. Nice work. Produce a few more of them you've got 2 buyers in Canada if you do!!

Keep up the work great ideas nicely put together

Thanks very much canadiana4! I actually ordered a used B8 front bumper that had been wrecked and "fixed" by some shop in Minnesota or something like that. Super sketchy, but I knew I was going to chop it up anyways so I didn't care. The cost is really in the labor. Materials wise the conversion costed me $800 after all the SEM products and paint, but the time it took to mold all three together was ridiculous and unless I made a mold of this and did it out of fiberglass I'm not sure it'll ever be financially worth it to reproduce. BUT, if that ever happens I'll definitely let you know! Cheers

curti869
02-01-2017, 12:17 PM
Did you keep that big plastic piece that came out of the back, the tire cover part... I really need one and by the way sweet wagon man. Also are you happy with the muffler delete, I want to do it but kinda scared it will be too loud