Audi CQ Rally Build Hello Everyone, I'm new to the site, was referred over here by A.J who's building/built an old audi himself and has been giving me some advice on some audi forums. Background on the car: Davescq.wordpress.com Audi Forum topic: http://theprojectpad.com/viewtopic.php?f=11&t=1581 This is my first stage rally build, I've been a co-constructor on a few lemons car builds but that's about it. Goals for the car currently: Tear it down to basics and rebuild what I have to properly and distribute money carefully... "OEM-esque" suspension to start to save money Since I'm a true novice, I'll be treading lightly around power mods... Cage may be delayed until I get some road miles on the car.... tbd Current State of the car: [img]https://lh5.googleusercontent.com/-E9bIkSSaVVA/VT2C-NfeQ0I/AAAAAAAABFs/fkd1cbi6ak0/w1161-h871-no/4.26.15%2B-%2B9[/img] [img]https://lh3.googleusercontent.com/-kLLy7O2mxME/VT2C-PnuGxI/AAAAAAAABFU/SrBn-CAy8A8/w1161-h871-no/4.26.15%2B-%2B2[/img] Still removing sound deading and garbage from the interior and simplifying the wiring harness. Rear suspension has been dropped out, front suspension has been mostly disassembled, engine has been run for a bit (first time in about 6 years) - and will be removed with the trans soon. Some big current questions I have: How do I source seats without breaking the bank (is that even possible?) I want the side head protection and the cheapest I've been able to find is like 700 a seat :-\ Fuel lines... mine are completely rusted and require replacement. I heard people running them inside the car? Also looking for some details on running the fuel pump on quick disconnects. What to do with my Drivers window which is inoperable. Rules make it sound like they have to be able to go up and down? I was originally thinking of doing a polycarbonate replacement for the drivers side only for now. car was sold to me with the window looking like this: [img]https://lh5.googleusercontent.com/-CSGvgzQzVbM/VTeZXFAZm0I/AAAAAAAABC0/yXZa-84YWEs/w1161-h871-no/CQ%2B4.21.15%2B-%2B6[/img] Thanks in advance! :beer: https://www.rallyanarchy.com/phorum/read.php?5,106053,106053#msg-106053 Tue, 14 Apr 2026 13:01:47 -0500 Phorum 5.2.15a https://www.rallyanarchy.com/phorum/read.php?5,106053,114476#msg-114476 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,114476#msg-114476
I crimped the lugs on the ends with Vise-Grips. Worked at least as well as using a smooshing die in the 20 ton press. Heat shrunk too, of course.]]> Pete Construction Zone Fri, 06 Jan 2017 19:03:24 -0600 https://www.rallyanarchy.com/phorum/read.php?5,106053,114447#msg-114447 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,114447#msg-114447
I'm trying to size my primary wire from my battery to kill skitch. The run looks like it will be about 14.5 ft. I'm trying to figure out what kind of amperage I can expect through this cable to size the wire. It seems like it should be in the 1 or 2 awg range. sound right?

I'll post up a more detailed update in the future... but how about a teaser...

https://cnt-01.content-na.drive.amazonaws.com/cdproxy/templink/A9ffw_GV67IHNnZEcBlBvlQyc1IooYBbwgpu3vnAsSgpX92IB?viewBox=2560,1920

no cage for now, I guess I'm thinking RallyX and shakedown for the immediate future...]]> dalspaugh Construction Zone Thu, 05 Jan 2017 10:49:50 -0600 https://www.rallyanarchy.com/phorum/read.php?5,106053,112275#msg-112275 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,112275#msg-112275 aj_johnson Construction Zone Wed, 01 Jun 2016 14:20:16 -0500 https://www.rallyanarchy.com/phorum/read.php?5,106053,112273#msg-112273 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,112273#msg-112273
But anyway, who cares about the serious stuff, let's look at the project.

I've been busy since my last post although my pictures don't really tell the story....
I've got the motor and trans mated up again which is nice. only waiting on new mounts to call it ready to be dropped in!



meanwhile on the chassis side of things, I've got the bay painted, and I've started installed pieces. It actually goes together quite quickly... steering rack and booster in.



I've also been getting the fuel lines tidied up, AN sure looks pretty but DAMN it adds up so fast... $$$







I forgot to take a picture but I've got the 4 coilovers (OEM) built up and ready to be dropped in. Man I hate spring compressors...

I got the front brake lines routed. I had to sort of guess where a good spot for the bulkhead fitting would be... we'll see how that goes later when its time to order the last few feet of brake line to the caliper.



Also had to make up a temp blockoff plate for the climate control intake. I eventually would like to get a manual set up but theres no time for now.



I'm also making this fuel line cover for where the fuel fittings leave the fuel tank then get immedietiely rerouted into the car. There's about a 5 inch hole in the underside there that needs to be protected from the gravel machine gun. Just need to weld this up and add a fitting so I can see if/when I have a fuel leak from that area.



]]> dalspaugh Construction Zone Wed, 01 Jun 2016 14:05:24 -0500 https://www.rallyanarchy.com/phorum/read.php?5,106053,111773#msg-111773 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,111773#msg-111773
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dalspaugh

This was a HUGE pain in the ass and time suck. Never again, but its done now:


Continuing tonight for the 4th day in a row!

I did that fancy wrap on my turbo header. I agree, never again. I'll pass on the advice I got too late also: soak it in water and wrap it wet. If you re-nig, you'll know.

For me, I'll send my stuff to Swain Tech before I use that exhaust wrap again.]]> Dexter Construction Zone Tue, 10 May 2016 19:44:39 -0500 https://www.rallyanarchy.com/phorum/read.php?5,106053,111757#msg-111757 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,111757#msg-111757
Weatherproof (weld up sunroof, plug antenna hole, weld up open rocker, seal airbox intake)
Rolling (Build coilover assems, install bushings, build front/Rear Suspension assems
Running (Install Motor / Trans / Wiring)
Driving (All of the above things need to work + Driveline, Seat (old Audi seat)
Leagal (Headlights, bumpers, signals etc.)

Tick tick tick...

Also may be looking for some wrenching space if anyone knows of something available at a decent price...]]> dalspaugh Construction Zone Mon, 09 May 2016 13:29:03 -0500 https://www.rallyanarchy.com/phorum/read.php?5,106053,111756#msg-111756 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,111756#msg-111756




















Then I also decided to use the grinder to cut out the remnants of the battery tray and some other bracketry that is long gone. It's looking almost certain that I will be moving out to the Seattle area at the end of June so I've been working hard to get this car water tight, rolling, assembled - SOMETHING so that I doing get stuck paying for a garage on the east coast while I'm thousands of miles away.

Other things done:
Every gasket besides the Head gasket has been replaced on the engine
New Injectors with Orings
Turbo motor windage tray and oil filter housing (with cooler ports)
New clutch installed
Wrapped exhaust manifold installed
New Knock Sensors
New Vapor/Vent line
So many other small jobs
New Fuel supply and return lines shown here



Started digging into a rusty rocker corner




New Motor Grounds


This was a HUGE pain in the ass and time suck. Never again, but its done now:


Continuing tonight for the 4th day in a row!]]> dalspaugh Construction Zone Mon, 09 May 2016 13:00:45 -0500 https://www.rallyanarchy.com/phorum/read.php?5,106053,110771#msg-110771 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,110771#msg-110771


oh well, on to welding, and go easy - I'm a beginner:

Prep:


More Prep:


Total welding for the morning:


Close ups:






But yeah, this section really isn't too bad since its exposed with no adhesive. Stay tuned for more.

Other things:
Installed a new fuel pump in the OEM location (in-tank)
Have a plan for running the fuel lines inside the car, will post pics soon
found the right orings for the new injectors, need to buy more
new EGR gasket, blockoff plate installed
reinforced the stamped inner tie rod pin piece, first coat of paint on
removed OEM flywheel, lightweight flywheel on the way

LOTS more parts on the way - time to kick this project into gear... I want to drive it this year!]]> dalspaugh Construction Zone Mon, 29 Feb 2016 12:49:55 -0600 https://www.rallyanarchy.com/phorum/read.php?5,106053,110769#msg-110769 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,110769#msg-110769
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aj_johnson
Make friends with your local HVAC shop. They have a huge brake and will 90 up a couple strips of steel for nothing more than a 6pack of tall boys. (If you don't feel like hand bending that is)

Not a bad idea, and at work we even have a small break. But i was looking at it this weekend and the pieces will be small enough that I don't think it will be too bad to each piece by hand since each will pretty much be unique.]]> dalspaugh Construction Zone Mon, 29 Feb 2016 12:27:48 -0600 https://www.rallyanarchy.com/phorum/read.php?5,106053,110742#msg-110742 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,110742#msg-110742 aj_johnson Construction Zone Fri, 26 Feb 2016 09:38:12 -0600 https://www.rallyanarchy.com/phorum/read.php?5,106053,110741#msg-110741 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,110741#msg-110741
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john vanlandingham
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dalspaugh
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john vanlandingham
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dalspaugh
not totally what I wanted to hear about the blue lines although I can't say I wasn't partially already thinking it...

In the continued spirit of not wanting to go through hell to remove the chassis adhesive over those blue lines... what about laying in 1/2" x 1/2" angle and then welding the two sides??

16g would do fine for the L strip. I do that along the floor to sill junction--a wek and sometime sketchy area.

Hmm... I'm not seeing any angle thinner than 1/8" thk. Would make for some poor welding... .125" angel to (probably) .060" chassis steel....

Are you talking about 16 gauge flat strip John?

Yeah. The CAR is stamped out of crap less than 1.0mm--around 0,9 or about 036"
So 16g or .0625" is arout 50% thinker...so a strip hammered over the edge of a table, then tacked on one side, hammered to fit as you go along the seam
easy!

I like this. I like this a lot. Thanks John! Stay tuned....]]> dalspaugh Construction Zone Fri, 26 Feb 2016 09:17:46 -0600 https://www.rallyanarchy.com/phorum/read.php?5,106053,110706#msg-110706 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,110706#msg-110706
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dalspaugh
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john vanlandingham
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dalspaugh
not totally what I wanted to hear about the blue lines although I can't say I wasn't partially already thinking it...

In the continued spirit of not wanting to go through hell to remove the chassis adhesive over those blue lines... what about laying in 1/2" x 1/2" angle and then welding the two sides??

16g would do fine for the L strip. I do that along the floor to sill junction--a wek and sometime sketchy area.

Hmm... I'm not seeing any angle thinner than 1/8" thk. Would make for some poor welding... .125" angel to (probably) .060" chassis steel....

Are you talking about 16 gauge flat strip John?

Yeah. The CAR is stamped out of crap less than 1.0mm--around 0,9 or about 036"
So 16g or .0625" is arout 50% thinker...so a strip hammered over the edge of a table, then tacked on one side, hammered to fit as you go along the seam
easy!]]> john vanlandingham Construction Zone Tue, 23 Feb 2016 13:59:55 -0600 https://www.rallyanarchy.com/phorum/read.php?5,106053,110700#msg-110700 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,110700#msg-110700
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john vanlandingham
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dalspaugh
not totally what I wanted to hear about the blue lines although I can't say I wasn't partially already thinking it...

In the continued spirit of not wanting to go through hell to remove the chassis adhesive over those blue lines... what about laying in 1/2" x 1/2" angle and then welding the two sides??

16g would do fine for the L strip. I do that along the floor to sill junction--a wek and sometime sketchy area.

Hmm... I'm not seeing any angle thinner than 1/8" thk. Would make for some poor welding... .125" angel to (probably) .060" chassis steel....

Are you talking about 16 gauge flat strip John?]]> dalspaugh Construction Zone Tue, 23 Feb 2016 12:46:07 -0600 https://www.rallyanarchy.com/phorum/read.php?5,106053,110690#msg-110690 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,110690#msg-110690
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dalspaugh
not totally what I wanted to hear about the blue lines although I can't say I wasn't partially already thinking it...

In the continued spirit of not wanting to go through hell to remove the chassis adhesive over those blue lines... what about laying in 1/2" x 1/2" angle and then welding the two sides??

16g would do fine for the L strip. I do that along the floor to sill junction--a wek and sometime sketchy area.]]> john vanlandingham Construction Zone Tue, 23 Feb 2016 08:50:18 -0600 https://www.rallyanarchy.com/phorum/read.php?5,106053,110689#msg-110689 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,110689#msg-110689
In the continued spirit of not wanting to go through hell to remove the chassis adhesive over those blue lines... what about laying in 1/2" x 1/2" angle and then welding the two sides??]]> dalspaugh Construction Zone Tue, 23 Feb 2016 07:24:29 -0600 https://www.rallyanarchy.com/phorum/read.php?5,106053,110680#msg-110680 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,110680#msg-110680
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alkun
That blue line is the one you really need to do. Also should do a tube from strut tops stitched along the firewall.

I hid this tube on the rain tray side.]]> aj_johnson Construction Zone Mon, 22 Feb 2016 22:14:13 -0600 https://www.rallyanarchy.com/phorum/read.php?5,106053,110679#msg-110679 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,110679#msg-110679 alkun Construction Zone Mon, 22 Feb 2016 20:57:41 -0600 https://www.rallyanarchy.com/phorum/read.php?5,106053,110677#msg-110677 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,110677#msg-110677
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dalspaugh
Alright, getting back at this thing. Holidays and a old german DD have robbed me of my last few months! Want to get ya'lls opinion on some proposed welding I'm doing. I'm definitely looking at option B here.

Focused on the front end right now because it means I don't have to deal with liquid N and its the part of the car gets the most stress and it may soon be holding up the engine going back in the car (what a crazy thought)

red lines are weld lines, blue are joints that I'm planning to leave






1/2" weld every 1 1/2" seams and joints...that's the norm...The welding goes quickly, the cleaning...not so quick.. But is IS an amazing difference when done.



]]> john vanlandingham Construction Zone Mon, 22 Feb 2016 16:13:39 -0600 https://www.rallyanarchy.com/phorum/read.php?5,106053,110674#msg-110674 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,110674#msg-110674
Focused on the front end right now because it means I don't have to deal with liquid N and its the part of the car gets the most stress and it may soon be holding up the engine going back in the car (what a crazy thought)

red lines are weld lines, blue are joints that I'm planning to leave







]]> dalspaugh Construction Zone Mon, 22 Feb 2016 13:50:40 -0600 https://www.rallyanarchy.com/phorum/read.php?5,106053,109230#msg-109230 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,109230#msg-109230
The separation of the seam between the frame rail and fender liner will get some add'l welding on both sides of the car other than that I'm repairing as needed.

I may have been a little peeved when posting earlier. If you decide not to stitch I would keep an eye on this particular seam. Todd was telling me one of the rallyx cars has managed to wrinkle that pretty good.]]> aj_johnson Construction Zone Thu, 12 Nov 2015 15:10:29 -0600 https://www.rallyanarchy.com/phorum/read.php?5,106053,109226#msg-109226 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,109226#msg-109226 Miller 110v with 030 wire will not sweat too much if the power supply is good ie not 16g wires in the wall and at the end of the 100ft extention cord with 18g wires.
Good juice to welder and 030 and everything will go fine

Death ray cause those Howdis use the same rubberoid undercoating crap like the Xratyties do and that stuff is a major pain.. Dry ice, no its lame--liquid contacts the surface, piles of ice may NOT contact may be 2-5 mm off the surface so it has air insulation.. Liquid N is so cool its KEWL.
And quick....
Time is money.

You could do LOCAL welds on stressed areas..]]> john vanlandingham Construction Zone Thu, 12 Nov 2015 11:14:39 -0600 https://www.rallyanarchy.com/phorum/read.php?5,106053,109224#msg-109224 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,109224#msg-109224
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vbares
This is a point of reference - it is only 1 point - so major decisions should not be made solely on that 1 point. Important is to understand the difference between the b2 and b3 builds - which I do not.

My 4k has 43 documented rallies on it - some dnf's, mostly mechanical, but certainly I can see that there were a couple of significant repairs made to the shell prior to my acquiring it.

It is not seam welded.

My understanding is that the B3 is better chassis than the B2.

Even when this car was fully loaded, I've never been able to get to sit perfectly on 4 jack stands. this is obviously the fault of my garage but it should say something to the stiffness of the chassis.

But regardless, AJ's chassis is quite similar to the one I'm using, should be the same everything forward of the floor pan...

If I go option B... I guess I could use Dry Ice to conquer the body adhesive crap? that stuff looks mighty durable and it was slowing down my fancy ass dewault grinder whenever I touched it while taking out the vibration dampening material]]> dalspaugh Construction Zone Thu, 12 Nov 2015 09:53:35 -0600 https://www.rallyanarchy.com/phorum/read.php?5,106053,109223#msg-109223 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,109223#msg-109223
My 4k has 43 documented rallies on it - some dnf's, mostly mechanical, but certainly I can see that there were a couple of significant repairs made to the shell prior to my acquiring it.

It is not seam welded.]]> vbares Construction Zone Thu, 12 Nov 2015 09:48:16 -0600 https://www.rallyanarchy.com/phorum/read.php?5,106053,109222#msg-109222 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,109222#msg-109222
110 welder should be ideal for the job. Keep fire extinguisher handy.]]> aj_johnson Construction Zone Thu, 12 Nov 2015 09:34:04 -0600 https://www.rallyanarchy.com/phorum/read.php?5,106053,109221#msg-109221 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,109221#msg-109221
http://audi.7zap.com/en/usa/audi+coupe+quattro/couq/1991-141/8/]]> dalspaugh Construction Zone Thu, 12 Nov 2015 08:15:37 -0600 https://www.rallyanarchy.com/phorum/read.php?5,106053,109220#msg-109220 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,109220#msg-109220
Fine. Consider this topic open for discussion. Let's talk through some of the hoops I'm gonna have to jump through here...

Option A - Do it the right way
Prep
  1. Make a spit for the car so that Dave doesn't hate his life trying to get the globs of undercoating off
  2. Remove the doors, Mount the car to the spit
  3. Ask kindly for John's LNDR (http://www.rallyanarchy.com/phorum/read.php?5,6465,page=3)
  4. Rent a tank of Liquid Nitrogen (maybe the most fun sounding part of this...) hope that its not 500 pounds of it... in the dead of friggen winter...
  5. Use the LNDR to get the shit off the bottom and the seals
  6. Prep again by grinding and cleaning planned welded areas (of course, burning through my already quite pretty painted areas... (this is why we can't have nice things)
Welding
Using my cute 110V Lincoln MIGer, weld something like 400 stitch welds, run my little baby tank out of gas like 8 times and prolly toast this cute li'l welder.

Finish
Keep the areas clean until the spring where it would actually be warm enough to paint them...

Option B - "Do what I can - easily"

I'm thinking this gets me away from having to deal with all the crud under neath the car... Basically do anything in the engine bay since there's currently no engine in there... Do some of the floor pan / Door sill areas from the top that are currently very easy to get to.


This is craziness... Isn't one of those rally sayings something like: "get on stage as quickly as possible"? this seams (pun intended) to be going in the opposite direction of that...

Real questions about this whole thing:
Does this list actually capture anything remotely close to what this job entails?
How many small children am I going to want to kill doing this job?
How many small children am I going to want to save after first few rallies?
My garage only has 110, is this a real problem?
I don't have funds for a "real" welder, is this a problem?
I'm an amateur welder at best, is this a problem?
Liquid Nitrogen, is it fun?
Am I going to lose my mind building this car? Answer: Yes]]> dalspaugh Construction Zone Thu, 12 Nov 2015 08:08:31 -0600 https://www.rallyanarchy.com/phorum/read.php?5,106053,109218#msg-109218 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,109218#msg-109218
I'll put it on a hoist tomorrow and try to snap some pics, but lets start planning for some reinforcement of your car right now! this wasn't an area that I'd even looked at when I did some minimal stitching.

There is a chance the subframe is tweaked as well will have to swap it out and see what things look like.]]> aj_johnson Construction Zone Wed, 11 Nov 2015 23:50:53 -0600 https://www.rallyanarchy.com/phorum/read.php?5,106053,109211#msg-109211 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,109211#msg-109211
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wildert
I bet there are a few items that I would give lower priority than stitch welding.

I know I am happy I did it on my car...
I have multi point cage extending to the front towers (our regs are not as insane as the US ones), tie ins here and there, etc.
We do some jumping - and it is on rather stiff tarmac suspension (since we rally mostly on tarmac :)).
Also I haven't spent a lot of money on fancy suspension - more like "get the stuff that works and lasts".
Still - after doing a +100 mph jump at the last event, I checked the seams in the front wheel tubs, and it still does shift a bit as can be seen in the paint. Just half a millimeter - but it is there - and this car is stitch welded.

So far the shell has lasted more than 10 years - I wonder how long it would have lasted without stitching it.

Wildisen, I put 10 hard years and 10s of thousands of miles practice on my first car, the old 69 Saab...I knew it was stronger by serious degree than modern flimsy things like anything from the 80s but I thought you just do it.. A Golf pervert I knew in Sweden, Jonas Danielsson from Märsta said he's asked some old guy if he should weld when he started building his Golf--when he had sold his 96 (that is how I met him---I was buying some of his old stuff (steel flywheel and motorsport pressure plate and some other junk) He said the old guy said "You can take some time now, maybe 20-25 hours, and stitch it and the shell will last maybe 2 years of hard use and give no problems....OR you can skip it and go straight to rallies and when parts bend and rip, THEN you can hammer them straight, weld in a patch and in 2 years you will have spent maybe 25 hours welding. The difference is the amount of repairs to things, the amount of parts fallen off and damaged and the DNFs you have because of parts ripping and falling off, and the entry fees and transport to those events...Your choice"

But Like you Danes, the Swedes are Lutherans in culture..This means it is an accepted premise that if you shall have some fun you must pay, you must suffer. That is the nature of the world.

WE are Merikuns...The culture was once a "Protestant" culture..Hard work, and deferral of gratification was the cornerstone of what made Merikuh grape.
But that faded and was replaced by the current "Consumer-Capitalist" economy. The one unbending rule is the instant gratification of any and every whim...Its what won WWI (on this very day 97 years ago) and was the source of America singlehandedly winning WWII, and why we beat the evil Soviet Union, and defeated worldwide Comma-nist Conspiracy to impose its satanic ideology on us.

Suggesting doing something NOW for the benefit of having something that might last 10 years is nothing short of un-American if it means delaying entering an event..

I appreciate you suggesting what you did. I always appreciate your input..I have advocated thorough going stitch welding in the past--and done I don't know but maybe 10 cars...
Since we are privateers it seemed to make sense...

But then I saw the error of my ways..and began suggesting more or less just what you are saying sorta. "Weld when you're there"..so inside the car at cage time? Weld what's easy... Later after entering event with shitty old worn out motor and you blow it up so the engine and box are out? Weld when you're there. Did the subframe in the rear rip and the links and arms go boing cause they were not looked at? Weld when you're there..

But even that is excessive I now understand..experienced guys who have done 3 whole events in the last 10 years say the worst thing they ever did was to listen to me...so since we're saying the same thing in essence, we must both be wrong..
If I come and visit Danmark sometime, please remind me to slap you on the side of the head..I think we call that a "bitch slap" but I'm not so good with current merikun thought. Obviously..
Then you can return the favor.


Happy Armistice Day...the 11th Hour of the eleventh day or the eleventh month...97 years ago..
And the guns went silent.]]> john vanlandingham Construction Zone Wed, 11 Nov 2015 13:00:24 -0600 https://www.rallyanarchy.com/phorum/read.php?5,106053,109205#msg-109205 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,109205#msg-109205
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dalspaugh
I see the need, and I have the want to get in there in stitch weld and make this chassis extremely robust - but for now it'll have to wait. There's just not enough time to get it all done. Winter is coming here in NE and that'll mean an even slower pace than I'm already working at - who the hell wants to be in an unheated/uninsulated garage at 10-30 degrees? Now I understand people are working with less, and hats off to them...

Anyway, the car requires a ton more work and if I have any hope of making it to an event in '16 - even a rallyX, I better keep the pace up and the scope limited.

Not to beat a dead horse, but maybe consider re-scoping then...
Stich welding is so very basic, and takes a lot of taking-car-apart to get to, not to mention messing up paint job in the area.
Doing the actual welding is not THAT bad time-wise - getting to where you are able to do the welding, and cleaning up afterwards takes time.

So if you are "in there" for other business, I would consider doing it anyway, even if it means not doing some other things right now.

I haven't read through the thread in detail, but I bet there are a few items that I would give lower priority than stitch welding.

I know I am happy I did it on my car...
I have multi point cage extending to the front towers (our regs are not as insane as the US ones), tie ins here and there, etc.
We do some jumping - and it is on rather stiff tarmac suspension (since we rally mostly on tarmac :)).
Also I haven't spent a lot of money on fancy suspension - more like "get the stuff that works and lasts".
Still - after doing a +100 mph jump at the last event, I checked the seams in the front wheel tubs, and it still does shift a bit as can be seen in the paint. Just half a millimeter - but it is there - and this car is stitch welded.

So far the shell has lasted more than 10 years - I wonder how long it would have lasted without stitching it.]]> wildert Construction Zone Wed, 11 Nov 2015 03:12:13 -0600 https://www.rallyanarchy.com/phorum/read.php?5,106053,109096#msg-109096 Re: Audi CQ Rally Build https://www.rallyanarchy.com/phorum/read.php?5,106053,109096#msg-109096
**All these steps were performed after much treatment with MAP Torch and PB Blaster!**

eyeball center and punch it with a center punch.


I have left-hand thread bits just for this purpose, so dril it out, pay careful attn to depth so as not go into the head...


Tap in extractor to seat...


then, CAREFULLY crank CCW, I say carefully because the extractors can only take so much and you REALLY don't want to break the extractor off in the stud. If it feels like its not going to move, reapply lots of heat and penetrating fluid. You can also step up to a bigger drill bit and bigger extractor... but in the end.. whoala!


Also, I should note, that this job mamde me buy this fancy extractor set... but having 3 early 90s Audis in NE, I'm sure will allow me to get my money back... (also I got it on Amazon Warehouse deals for a discount)

http://smile.amazon.com/gp/product/B000EEX644?psc=1&redirect=true&ref_=oh_aui_detailpage_o07_s00]]> dalspaugh Construction Zone Thu, 05 Nov 2015 07:52:59 -0600