Figured it's about time I post

[PringlesInVic]

When I swapped by back door it was very easy, the time consuming part was getting the gaps aligned, but that's something you can't rush. But, mine was a little easier as I just swapped out the whole window assembly. My new door already came trimmed and sealed. I bet you can do it no problem.

[Seerlah]

Yeah, I only have the door skin replacement. Swapping everything else. It's the alignment that has me on edge.

[fR3ZNO]

If you have a Bentley manual, the entire door alignment procedure is shown.

[thedanplasse]

Ghia is getting some love. Off to the metal shop for replacement of panels we have already, and fabrication of those that aren't available. It's been blasted, and coated in epoxy primer to seal in the bare metal.

[Seerlah]

If you have a Bentley manual, the entire door alignment procedure is shown.

Dirty blonde hair moment...with rock star streaks. Didn't think to even look in the manual

[thedanplasse]

Dirty blonde hair moment...with rock star streaks. Didn't think to even look in the manual

That's being said... I need one. Know of anyone selling one cheap?

[Seerlah]

I would try ebay, or torrent it free on The Interwebz.

[thedanplasse]

Bought this a while back for $40 thought the paint was trashed. Spent a few hours wet sanding, polishing, and sealing it, and this is the outcome. I'd say about 90% of the imperfections came out. Not too bad, and I think I can live with it. Always trying to learn new things, and honestly...paint correction is pretty fun. (although I'm far from mastering it)

[xdewaynex]

Thats pretty amazing, hard to believe its the same color.

[thedanplasse]

Thats pretty amazing, hard to believe its the same color.

Keep in mind that the pictures were also taken at different points in the day, so lighting was a factor. But, I was pretty impressed with the results.

[thedanplasse]

Stopped by the engine shop today to drop off my new crank gear because my old one was starting to shear. Just waiting on me to throw more money at them, and to pin the crank that they were waiting on me to drop the gear off for lol. If anyone on here is around the Warwick, RI area...I highly recommend R Johnson & Son's, they're super knowledgeable with Audi's, and do great work.

[thedanplasse]

Finally paid off the block, and got it back home.

[thedanplasse]

Spent a little time at the shop blasting some more block parts.

[thedanplasse]

Again. Just another media blasting update. Took the intermediate shaft apart, and cleaned the pieces up, already painted them black. New seals, and o rings going back on. Then re installation begins. (Not pictured) I finally got around to removing all the stripped Allen bolts holding both pulleys on the power steering pump. Said pulleys have been blasted and painted as well. Pump will be next.

[xdewaynex]

Coming along nicely. My block is still at the machine shop, just waiting on the call. What freeze plug did you get for the hole where the block breather went? Only thing I could find was a rubber expansion plug.

[thedanplasse]

Coming along nicely. My block is still at the machine shop, just waiting on the call. What freeze plug did you get for the hole where the block breather went? Only thing I could find was a rubber expansion plug.

40mm from any auto parts store. I had one in there previously, but took it out, and threw it away to run the stock breather. Until I found the adapter for a catch can line...so I put one back in lol. I used some sealant around it before I tapped it in just for peace of mind. Don't want that falling in at 8500rpm.

[xdewaynex]

I was in a hurry when I picked up the expanding one. Yea that would be pretty disastrous.

[thedanplasse]

I was in a hurry when I picked up the expanding one. Yea that would be pretty disastrous.

I think I paid like $3.50 for a new one at CAP, fits snug and looks neat.

Spent a little time last night finally working on the rear calipers I have been avoiding for the last 6 months. I couldn't get the inner snap ring back in, even after several attempts with different pliers. I ended up modifying a set of Gearwrench snap ring pliers to fit in there. Managed to get the ring in, but will have to wait until tomorrow to use the caliper piston depressors at work to get them all buttoned up.

Completely stripped the calipers down. Re-surfaced the Piston, and cylinder area. Blasted the bracket and calipers. Painted them imola yellow, and replaced all seals, and o-rings with a centric rebuild kit. Ordered new slide pins, boots and bolts as well. Should be better than the day they were built, when matched up with apikol brackets to run 300mm B6/B7 rear rotors.

[Joe Jr.]

stuff looks good. your car will be clean once you get it all back together, for sure!

[thedanplasse]

stuff looks good. your car will be clean once you get it all back together, for sure!

Thanks, That was my plan. I wanted everything to be clean, Stripped down to bare metal, and painted metallic black. Any gaskets, and o-rings will be replaced. Same thing with the suspension, all bushings will be replaced with either high density poly, or aluminum. It won't be a daily driver so the cabin noise/vibration won't matter much to me. I want it to perform, and handle as best as it can.

[fR3ZNO]

Kinda late now, but I got a set of motorcycle master cylinder snap ring pliers that worked great for when I rebuilt B6 S4 rear calipers.

Clicky Click

Calipers look great btw, I would be so paranoid about getting brake fluid on them lol

[thedanplasse]

Kinda late now, but I got a set of motorcycle master cylinder snap ring pliers that worked great for when I rebuilt B6 S4 rear calipers.

Clicky Click

Calipers look great btw, I would be so paranoid about getting brake fluid on them lol

>_< I'm afraid of that too..Going to have to be very careful when I bleed them. But I also did my R32 calipers in brown to match the interior of my GTI when I did them, so I have a little experience. I'll post a picture of what I used to get the snap ring back in when I get back up to my parents house this saturday. Honestly even with the pliers it was hard to get the ring in until my dad came, and helped me with an extra set of hands.

[thedanplasse]

Got the Piston in. Word of advise. Put the boot on the bottom of the Piston, and put the boot in the caliper. When depressing the Piston in it'll slide in to place. Just so you don't have to disassemble the caliper to take the Piston back out :banghead:

[thedanplasse]

NLS breather adapter came in.


Now to start building my catch can setup. All black nylon braided hoses, -10 fittings, to a gloss black vented catch can mounted to the false firewall.

[thedanplasse]

Got my uncle (and his machine shop) involved. Making an oil drain spacer for the Holset. I know you can buy them, but I figured....why not make it ourselves. (mostly my uncle....ok I just watched). Made from cast iron for heat management.

[thedanplasse]

Got the final coats of metallic black on the block. I'll be buying the intermediate shaft seal, and o-ring, and get that in. As well as the front and rear crank seals. Painting the oil pan metallic black (for asthetic reasons only) and putting that on as soon as I buy a new oil pump.

[thedanplasse]

Finally started throwing things back at the engine. Front crank seal, and flange gasket, Intermediate shaft with a new seal, and o ring. Block breather adapter with a new gasket, oil filter housing with a new gasket, and passenger motor mount bracket. Ordering a new water pump, and thermostat soon. Then start putting the accessory bracket on.


Blasted the oil pan, and hit it with a coat of metallic black. Once I buy a new oil pump, I'll bolt that back up too.

[rockbeau25]

Nothing more satisfying than seeing shiny, perfectly painted parts


Sent from my iPhone using Tapatalk

[PringlesInVic]

Not to nit pick, because it looks great and your doing an awesome job. But I'm wondering with all the effort and care you've taken. Why didn't you blast all you bolts too? You plan on painting them after the fact? Crank seal plate looks great, except for the rusty bolts.

And to clarify, this has nothing to do with Rad support bolts.

[thedanplasse]

Nothing more satisfying than seeing shiny, perfectly painted parts


Sent from my iPhone using Tapatalk

Thanks. I figured I would take the time to coat everything, and make them look brand new (but black) since everything is apart.

Not to nit pick, because it looks great and your doing an awesome job. But I'm wondering with all the effort and care you've taken. Why didn't you blast all you bolts too? You plan on painting them after the fact? Crank seal plate looks great, except for the rusty bolts.

And to clarify, this has nothing to do with Rad support bolts.

I knew someone would say something lol. I have been refinishing all the bolts I've been using, But I forgot to do those. Kinda figured that it'll be under a timing cover, and nobody will see, plus I was a little eager to start re-assembly. I may pull those out just to refinish them for you. Still not doing the rad support bolts for Devon.

EDIT: I just ordered all new bolts, and washers for both front, and rear main flanges from audi for you lol.

[PringlesInVic]

I knew someone would say something lol. I have been refinishing all the bolts I've been using, But I forgot to do those. Kinda figured that it'll be under a timing cover, and nobody will see, plus I was a little eager to start re-assembly. I may pull those out just to refinish them for you. Still not doing the rad support bolts for Devon.

EDIT: I just ordered all new bolts, and washers for both front, and rear main flanges from audi for you lol.

Lol, thanks. Your logic makes perfect sense, they are covered. And I totally get the desire to get everything together.

[fR3ZNO]

EDIT: I just ordered all new bolts, and washers for both front, and rear main flanges from audi for you lol.

there better not have been any core support to frame bolts in that order

[Joe Jr.]

when you're done with your ride, can i send mine out for some of that custom stuff? lol. Really nice work! Good to follow along.

[Joe Jr.]

there better not have been any core support to frame bolts in that order

Dave just 6 of my 8 new non rusty bolts ...lol...we better see some pics of those on the support...lol.

[thedanplasse]

there better not have been any core support to frame bolts in that order

I promise lol. I'm using the shitty ones I have. I wont even blast or paint them either.

when you're done with your ride, can i send mine out for some of that custom stuff? lol. Really nice work! Good to follow along.

It's nice having a full machine shop at your disposal.

Dave just 6 of my 8 new non rusty bolts ...lol...we better see some pics of those on the support...lol.

Whenever I get to putting the car back together I'll post a picture proving I used them.

[fR3ZNO]

Dave just 6 of my 8 new non rusty bolts ...lol...we better see some pics of those on the support...lol.

Oh, you'll see them. They'll be the nicest hardware on the whole car.

(if you're talking about my B5)

[Joe Jr.]

Oh, you'll see them. They'll be the nicest hardware on the whole car.

(if you're talking about my B5)

I was but this is thedanplasse's thread so i let it be..lol

[thedanplasse]

LOL! whoops. Fine.....I won't send you guys a picture...

[fR3ZNO]

No, we still want the pic as proof and to rustle Devon's jimmies

[thedanplasse]

For Pringles. All new bolts and washers for the front flange from Audi.