Audi CQ Rally Build
Posted by dalspaugh
John Vanlandingham Ultra Moderator Location: Ford Asylum, Sleezattle, WA Join Date: 12/20/2005 Age: Fossilized Posts: 14,152 Rally Car: Saab 96 V4 |
David Alspaugh Senior Moderator Location: Boston, MA Join Date: 04/30/2015 Age: Settling Down Posts: 66 Rally Car: '91 Audi Coupe Quattro |
A.J. Johnson Godlike Moderator Location: Pendleton OR Join Date: 01/07/2011 Age: Settling Down Posts: 1,381 Rally Car: 88 Audi 80 |
David Alspaugh Senior Moderator Location: Boston, MA Join Date: 04/30/2015 Age: Settling Down Posts: 66 Rally Car: '91 Audi Coupe Quattro |
David Alspaugh Senior Moderator Location: Boston, MA Join Date: 04/30/2015 Age: Settling Down Posts: 66 Rally Car: '91 Audi Coupe Quattro |
Got in the garage and started the welding. I found that my paint was peeling off the engine bay anyway, I'm guessing that's because of the cold dark and moist environment that the chassis has been in since It's been painted.
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! Blog about my history with the rally car written for non-automotive folk: davescq.wordpress.com |
David Alspaugh Senior Moderator Location: Boston, MA Join Date: 04/30/2015 Age: Settling Down Posts: 66 Rally Car: '91 Audi Coupe Quattro |
So! I have been busy although I haven't been giving the phorums much love. I'll let the pictures do much of the talking. I'm still a novice at best with this whole welding thing...
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! Blog about my history with the rally car written for non-automotive folk: davescq.wordpress.com |
David Alspaugh Senior Moderator Location: Boston, MA Join Date: 04/30/2015 Age: Settling Down Posts: 66 Rally Car: '91 Audi Coupe Quattro |
Dexter Clark Professional Moderator Location: Hemlock, MI Join Date: 12/28/2014 Age: Midlife Crisis Posts: 26 Rally Car: Rally all of the things |
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. |
David Alspaugh Senior Moderator Location: Boston, MA Join Date: 04/30/2015 Age: Settling Down Posts: 66 Rally Car: '91 Audi Coupe Quattro |
So its official, I'm moving to Seattle in a matter of weeks, I don't have a job secured so if there's someone looking for a mechanical engineer in the greater Seattle region... let me know! This also puts a pretty demanding timeline on the project... I need to get it in a decent state... ASAP.
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. 
 Blog about my history with the rally car written for non-automotive folk: davescq.wordpress.com |
A.J. Johnson Godlike Moderator Location: Pendleton OR Join Date: 01/07/2011 Age: Settling Down Posts: 1,381 Rally Car: 88 Audi 80 |
David Alspaugh Senior Moderator Location: Boston, MA Join Date: 04/30/2015 Age: Settling Down Posts: 66 Rally Car: '91 Audi Coupe Quattro |
Pete Remner Ultra Moderator Location: Cleveland, Ohio Join Date: 01/11/2006 Age: Midlife Crisis Posts: 2,022 |
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