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AUDI 80 rebuild- Open light

Posted by aj_johnson 
aj_johnson
A.J. Johnson
Infallible Moderator
Location: Pendleton OR
Join Date: 01/07/2011
Age: Settling Down
Posts: 1,353

Rally Car:
88 Audi 80


AUDI 80 rebuild- Open light
November 14, 2016 12:47PM
Good Morning everyone, lets try putting this in the correct area eh?

Finally getting around to rebuilding the Rally car after the roll at Idaho this year. I had initially planned on shelving the car for the winter to work on the Datsun. after the roll, plans have changed.

My little shop is a 25x25 space that isn't really big enough to do two side by side projects of the magnitude I have in mind for the Datsun and the Owie. So I took every part and piece for both cars shoved em in their respective cars. I started pulling out all the mix'n'match shelving, storage and too big workbenches acquired from garage sales and friends and sold, gifted and traded it all away. Sneaking in time from the family and house projects I managed to get new workbenches built, organizing shelves, and a workspace that just might house the mess I intend to create.

I'm tugging the Rally car down to a frame rack today to straighten out the strut tower that relocated itself then going to Start a complete refresh of the car moving into open light.
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Attachments:
open | download - EFFING Mess.jpg (48.2 KB)
EFFING Mess.jpg
open | download - More Mess.jpg (44.4 KB)
More Mess.jpg
open | download - Shop Bench 1.jpg (45.3 KB)
Shop Bench 1.jpg
open | download - storage.jpg (41.2 KB)
storage.jpg
open | download - Shop bench 2.jpg (41.8 KB)
Shop bench 2.jpg
open | download - Rolled.jpg (73.1 KB)
Rolled.jpg
aj_johnson
A.J. Johnson
Infallible Moderator
Location: Pendleton OR
Join Date: 01/07/2011
Age: Settling Down
Posts: 1,353

Rally Car:
88 Audi 80


Re: AUDI 80 rebuild- Open light
November 14, 2016 12:49PM
I've been slowly collecting parts and pieces as well as selling off a bunch of the old parts over the last couple of months. I think I've finally come up with all the bits and bobs to put together a really nice OL car.

Yanked the old 10v turbo and sold it and the spare motor to some dude in Salt lake. Picked up a NA 20v from a coupe quattro from a guy in california along with a whole bunch of other niceties.
Factory long tube header
Set of Piper Camshafts
Head with bigger holes going in and out of it
CNC machined large bore MAF, Machined Throttle body, Factory ECU with some fancy mapping
Balanced crank, flywheel, and Aluminum front pulley.

Also big thanks to Mike Hurst for his help in the repair process. I picked up a parts car to start swapping wrinkled and crushed parts off the rally car.

John once I get it off the frame rack I'll run through the suspension. I got fed up with the mess and made myself a promise that I wouldn't touch the car until the shop was ready to work in.


Really getting excited to complete the strip down and refresh.
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Attachments:
open | download - Engine out.jpg (55.2 KB)
Engine out.jpg
open | download - Repair Kit.jpg (54.6 KB)
Repair Kit.jpg
open | download - IMG_20161103_214558149[1].jpg (30.3 KB)
IMG_20161103_214558149[1].jpg
aj_johnson
A.J. Johnson
Infallible Moderator
Location: Pendleton OR
Join Date: 01/07/2011
Age: Settling Down
Posts: 1,353

Rally Car:
88 Audi 80


Re: AUDI 80 rebuild- Open light
November 14, 2016 01:01PM
One of the local body shops, hit a slow spurt and was kind enough to put the pig on the rack and see how bad things are. Other than the drivers strut tower everything else checked out and looked good. After I brought in a 24 pack of Heffe we pushed some tin around and got it to line up just right.

After towing the car home I went to town cutting spot welds and removing anything mangled or out of position. I still need to strip the rest of the parts n pieces out of the engine bay, but it's coming along with an hour of work here and there.
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Attachments:
open | download - IMG_20160618_090002667.jpg (50.5 KB)
IMG_20160618_090002667.jpg
open | download - IMG_20160618_090028525.jpg (32.1 KB)
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IMG_20161109_161103208.jpg
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open | download - IMG_20161113_161948329.jpg (50.9 KB)
IMG_20161113_161948329.jpg
Gravity Fed
Alex Staidle
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Location: Δx = ħ/2Δp
Join Date: 08/21/2009
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Rally Car:
1978 Mazda Rx7



Re: AUDI 80 rebuild- Open light
November 14, 2016 01:01PM
cant wait for round 2



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aj_johnson
A.J. Johnson
Infallible Moderator
Location: Pendleton OR
Join Date: 01/07/2011
Age: Settling Down
Posts: 1,353

Rally Car:
88 Audi 80


Re: AUDI 80 rebuild- Open light
January 16, 2017 11:10PM
EXTRA EXTRA Read all about it.

Moving again! (I hate moving) back to the Spokane area, new job within the same company, closer to the family. I'm in a mad scramble to finish all the nick nacky projects around the house done to get it on the market. May have some time while its up for sale to finish the car - All the necessary bits have been cut off, replacements cut and is ready to be welded back together.

In the meantime, I'm tentatively in the market for bumper tow enclosed trailer to use as storage, hauling to the next state. (and of course future rallying)

If we can come out as ahead as I think we can on this house, and with the perks of a move up I think there may be more racing than less in my future. (and probably bigger house projects)

Wish me luck and I'll be back as soon as the house is ready.
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aj_johnson
A.J. Johnson
Infallible Moderator
Location: Pendleton OR
Join Date: 01/07/2011
Age: Settling Down
Posts: 1,353

Rally Car:
88 Audi 80


Re: AUDI 80 rebuild- Open light
March 31, 2017 02:31AM
House is done. I have till June 1 to get er rocking. cleaning up in preparation for new bushings, stitch welding and getting the engine bay rocking. time to put the block on an engine stand and get it put together. Starting with the front end and moving backwards
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Attachments:
open | download - rebuild.jpg (43.4 KB)
rebuild.jpg
deaner
Dane Aura
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Location: Caldwell, ID
Join Date: 07/07/2013
Age: Settling Down
Posts: 337

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PS4 controller


Re: AUDI 80 rebuild- Open light
April 01, 2017 09:59PM
So she'll be ready for Idaho Rally yeah? Haha I know.... we've talked about this.
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aj_johnson
A.J. Johnson
Infallible Moderator
Location: Pendleton OR
Join Date: 01/07/2011
Age: Settling Down
Posts: 1,353

Rally Car:
88 Audi 80


Re: AUDI 80 rebuild- Open light
April 02, 2017 02:03AM
Quote
deaner
So she'll be ready for Idaho Rally yeah? Haha I know.... we've talked about this.

I'm going to try, but I wont be running with the move and all. I'd really like a to find a codrive for it though.

This cut and paste stuff is a real learning experience for me. the stitch welds are kicking my ass. the plug welds (filling the old spot welds) are pretty solid but the stitching took a little while to get the timing down with 2 different thickness pieces. I thing i've got a handle on it and I'm enjoying it which is a big plus.

Is there any pro's and cons to trying to put all the OEM core support and front cross member mounts back on? or should I just go to town with some square tube? I think cutting and pasting the factory mounts from the parts car would be faster, but with some creativity I think I could switch to a front mount radiator.

AJ
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Attachments:
open | download - fender 1.jpg (47.9 KB)
fender 1.jpg
open | download - fender 2.jpg (46.4 KB)
fender 2.jpg
open | download - fender 3.jpg (48.8 KB)
fender 3.jpg
open | download - fender 4.jpg (45.7 KB)
fender 4.jpg
deaner
Dane Aura
Infallible Moderator
Location: Caldwell, ID
Join Date: 07/07/2013
Age: Settling Down
Posts: 337

Rally Car:
PS4 controller


Re: AUDI 80 rebuild- Open light
April 02, 2017 11:00AM
Glad you've gotten the hang of it. It can def be pretty frustrating until it clicks. The more you do the better you'll get, just like anything else I suppose. Idaho is still looking for plenty of volunteers! You can come work road block with me at Grimes! I'll bring my welder and we can practice haha. smiling smiley

Front mount rad.... I was going that route with the AAN in my B2 until I scrapped the whole thing and went 1.8t. I had a decent sized griffin I was going to use and with the core support cut out, I could have def made it work. Looking back, between the cost of the griffin, materials to rec tube part of the core support and make a grill plus the time involved, I think I would have been better off just having a nice thick sidemount built for like $350-400. With as far out front as a front mount rad sits, a lot of the bumper beam has to be cut out which leaves the area between the headlights pretty much wide open for damage with even a small impact.

The nice thing about B3s is most of the core support is already removable. If it were me and I'm understanding you right, I'd make the factory support work so you don't have to monkey with rebuilding something that's already been built by the factory. Just my .02.
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john vanlandingham
John Vanlandingham
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Saab 96 V4



Re: AUDI 80 rebuild- Open light
April 02, 2017 11:45AM
No1 priority AJ: get it moving..does the upper rad support currently demount? I might give some thought to making it removeable using the new part and the remains of the old but not spend too much think time..Think instead what we'ze gonna do to make those top mounts work happily.



John Vanlandingham
Sleezattle, WA, USA

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aj_johnson
A.J. Johnson
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Location: Pendleton OR
Join Date: 01/07/2011
Age: Settling Down
Posts: 1,353

Rally Car:
88 Audi 80


Re: AUDI 80 rebuild- Open light
April 02, 2017 01:01PM
John, The whole shooting match is removable from the factory. Aside from the caps to the frame rails the whole front end disassembles as you see it here in about 20 minutes. It's one of my favorite things about the cars.
After sleeping on it- you are right KISS. Just put in a thicker radiator.
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aj_johnson
A.J. Johnson
Infallible Moderator
Location: Pendleton OR
Join Date: 01/07/2011
Age: Settling Down
Posts: 1,353

Rally Car:
88 Audi 80


Re: AUDI 80 rebuild- Open light
April 05, 2017 01:36AM
I managed to get about an hour and a half on the car tonight. Need to break out the grinder to get the frame rail caps the rest of the way off but progress is progress.

Impressively all the bolt holes for the front end line up with 0 persuasion so far. I must have guessed right somewhere or got just enough of the measurements wrong. Either way wrapped up with a smile tonight.
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Attachments:
open | download - front end check.jpg (43.6 KB)
front end check.jpg
open | download - front end check 2.jpg (47 KB)
front end check 2.jpg
Robert Culbertson
Robert Culbertson
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Location: Portland , Or
Join Date: 08/15/2010
Age: Party Animal
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Rally Car:
MK2 VW GTI



Re: AUDI 80 rebuild- Open light
April 05, 2017 02:05AM
You better go buy a lottery ticket!
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aj_johnson
A.J. Johnson
Infallible Moderator
Location: Pendleton OR
Join Date: 01/07/2011
Age: Settling Down
Posts: 1,353

Rally Car:
88 Audi 80


Re: AUDI 80 rebuild- Open light
April 05, 2017 02:14AM
Quote
john vanlandingham
No1 priority AJ: get it moving..does the upper rad support currently demount? I might give some thought to making it removeable using the new part and the remains of the old but not spend too much think time..Think instead what we'ze gonna do to make those top mounts work happily.

Been thinking about this quite a bit- subaru mounts make the most sense, but what I've got will work for the time being. I'd really like to make those adjustable mount's I've got on the workbench work but the stock pin is sooo skinny. Best case is to go play around with a chunk of aluminum and see if I can't remake the adjustable mount with a good sized bearing but running driving is most important.

Robert- it crossed my mind.
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aj_johnson
A.J. Johnson
Infallible Moderator
Location: Pendleton OR
Join Date: 01/07/2011
Age: Settling Down
Posts: 1,353

Rally Car:
88 Audi 80


Re: AUDI 80 rebuild- Open light
April 13, 2017 01:49AM
This has taken substantially longer than I thought. The cross member lines up but isn't welded yet. One side is ready but the other needs some massaging. Finding clamps to hold it in place is an exercise in creativity
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Attachments:
open | download - IMG_20170412_230335637.jpg (44.8 KB)
IMG_20170412_230335637.jpg
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