My long restoration of a 1983 Ur.

[4v6]

Have been a little delayed on this job due to other work needing to be done, like a new front door and frame prepping and painting for the house, but since thats all done now I'm almost free to get the final areas worked and I'm cautiously pencilling in a date of sometime in the coming week (weather allowing) to do the main body paint.
Was out in the garage at 5 am today doing some work to try and get every damned thing done, multitude of stupid little things that are being worked out as if theyre not done now theyll stick out like a sore thumb.

Only way to check for panel straightness that I can think of is to flood the prepped panel with clean water and wait for it to drain down and look for flaws in the dark....so thats what I've been doing, getting it finally ready for the big day.

Hopefully the rest of the panels will be this straight and this was the one I cut out completely so it might all work out yet. [;)]

[EDIGREG]

looks fantastic!!

[highlander69]

Looking great for sure.

I'm really looking forward to seeing it painted.

Cheers,

Craig

[4v6]

Thanks for the nice comments guys, its looking tentatively as though I may just get the exterior painted this coming week, we have some nice weather predicted ( so itll probably hurricane) just need to address any remaining issues and go for broke on this ( and boy am I ever-broke.)

Pictures of the either finished project or me in distress shortly.

[4v6]

Been a while since i updated this one, cars still not finished, going for the longest resto record....

Way back in 2014, after the paint was done, id started to install the engine bay components.
Id always hated the brake pipe routing so i relocated the brake bias valve to the left side of the car on a bolted on plate that sits where the orignal brake master/booster sat.
These are way tidier and not in the way of anything .





Id already done some work to tidy the engine up, strpped off all the acilliaries and head to check for wear and since the head wasnt ready to go back on anyway, i got the engine sited on its mounts.



Using my valve seat cutting gear i refaced all the valve seats.





The heads had everything needed, new guides, seals chain etc so should be good for a few miles.

The parts spend on this thing is horrendous.
Some parts are available, othere arent.
I replaced the wiper motor spindles and had to modify one to get the mech to work, drilled out the old spindles and fitted the new ones.
The old ones were, well, a bit shot.





Got new door seals.



Correct 205 dunlops.



Had to fabricate a coolant elbow out of stainless.



Also got a set of new oem horns.



New thermostat housing.



Door and boot graphics.



Refurbed wheels and new bolts.



Looking forwards ( no pun) i thought i should source some new foglights, the orignals wernt up to much.





Managed to shove it outside in the sun while i painted up some other bits.



I sourced new door pin switches and seals and new door locks and checkstraps, old ones had had it, were loose, noisy and worn.







New locks need new strikers!



Decided to fabricate a new bonnet safety catch.
This one was made by hand from a piece of scrap stainless.



Sourced a pair of brand new door electric mirros as the wiring on mine had been chopped about worse than ed scissor hands.





Oil cooler barcket to fit the new cooler...



http://i82.photobucket.com/albums/j256/4v6/audiquattro/P1160193_zpsdgxesdot.jpg

Found a replacement part for the rubber strip that seals the back of the bonnet (hood).



VW part number is 7HO823 737 D



A new stainless exhaust system got stuffed in the postbox to replace the lack of one....





Along with a new intercooler and oil cooler.



I managed to utilise part of the existing AAN downpipe and fabricated up the required piping to join to the new exhaust.



Just about all methods ive ever seen to install a 20 valve motor into a B2 chassis seem to have issues when it comes to induction pipe routing, especially air filters, many are to my eyes stuffed in as an afterthought and because its obviously tight in there.
I couldnt bring myself to just do that so hatched a plan to make the install look factory, or try to.

Using an Ur lower airbox and coupe quattro (kv engine) upper airbox plus a broken ur airflow meter i came up with this arrangement.
Doing it like this means I get to keep the oem maf and management and it wont look too wonky.











I also decided to use the orignal coupe gt ps pump arrangement.
I know many use the tandem pump but it seemed easier to just fabricate the barcket to suit the AAN and go from there.



All fits in fine and uses the stock hoses.



Also fabbed up the fuel lines to reroute them
Ive always thought the original lines that go over the intake were a sloppy looking solution so I made mine to fit in a bit neater.





The boost pipe from the turbo to the intercooler had to be similarly made up. This still has to have pipe welded on to accept the air from the recirc dump valve.





Fed up of poor earth wires and slow starting?
Get a replacement ground cable from VW.



7E0 971 793 C available from any VW dealer fro the princely sum of 7 ish english pounds.
Fits any T5 transporter and since its from a diesel, its thicker than the oem audi item and is insulated also.

Poweder coated bumper supports came back so the car went outside last week in the sun while i primed the plastic covers up.





Primered plastics... still have the rear apron left then i can colour them and clear them.



Current status. New wiring harness for lighting/starting has arrived and is being modified to suit the uk version .
Engine wiring next.
Painting of plastic aprons and bumpers also.

Maybe a start up later this year will herald the end of this nightmare...

[ringbearer]

Just amazing!

Love it, keep up the good work

[the german]

Looks fantastic, great work so far and looking forward to more!

[Dave]

Love the attention to detail! I'm impressed with the work thats been done!

[Afterthought]

it's really inspiring to see all that work on the sheet metal. amazing quality

[PRY4SNO]

Mega build! And big respect for your perseverance and attention to detail.

[vt10vt]

I love what you did with the airbox, very resto-mod/OEM+ looking, super clean.

Love the rest of the details too, keep us updated!

[Foscora]

Now that's a long, yet insane restauration ! Congratulations !

[4v6]

This is another project that had stalled due to life throwing a curve ball, but Id decided to make an effort to at least get it roadworthy.
As of my last posting on this project, the car needed some engine wiring doing to construct a better harness, Im still at that stage looking for a complete AAN 20 valve harness with all the terminations and fusebox intact.

One further bit of progress is the rear bumper cover/valance which has sat in the garage since it was primered and also outside for some period of time.
With other house related projects to do It hasnt been possible to get that done until recently and I repainted it , coloured and clearcoated it before finally fitting it to the car.
I must say it definitely finishes the rear of the car off nicely!

So Monday came and because I was in the mood to get some work done, I got the car out of the garage and set about finishing the prep on the rear apron, its been off the car since 2009.....lazy git I am.

I hadnt got any trestles to use to support it for spraying so I fashioned some hooks and cables and suspended it from the two ceiling hooks.
Then I made a plastic tent around the area to paint the thing.
That alone took hours, but by around 12 I was ready to put some colour on it.
A few more hours later and Id got the colour and the clear on and was basically playing with myself( not literally) to pass the time until I could remove it from the hooks and set it on the bench.
With the depressed air temps and the inevitable afternoon rain that swept in I was starting to wonder if Id get it shifted and get the car back in the garage, but I did make it eventually.

Fast forward a couple of days and Ive spent the morning reattaching the thing to the car.
Surprisingly, even though I replaced the old rear panel with a new one, it all fits quite well, thats considering the state the bumper was in (bent) and the plastics all cocked all over the place.
After a bit of monkeying around I finally got it fitted into place.
Still to do- re-drill the fixing holes in the plastic for inside the trailing edge of the arch, Ill likely use some plastic push fittings rather than any screws.

Im fairly pleased with how it looks, theres some paint rectification issues but during the afternoon sun that beamed down upon me I noticed a defect thats not going to just disappear and will have to be redone at some point.

I found that when the sun hits the paint on the apron it alters colour and has a purple flip to it.
Now, I specced the right colour basecoat for it so I can only assume thats how it is, Ive noticed this in the past with black also, but the Glasurit the rest of the cars painted in simply doesnt react like that and looks the same whatever angle you look at it from or how the sun hits it.
Its the same clear coat, so it has to be the basecoat thats iffy.

I do still have a small quantity of the original glasurit waterbase so Ill definitely end up redoing that part when the temps and conditions allow.
It looks fine until the sun hits it.
Most irking.

Anyways a couple of pictures to show the issue.

Looks ok from the rear.



Notice the apron on the rear, especially on the right side looks purple dont it?
For reference, the insert is the original waterbase colour and still looks the same colour sun or not.

Odd.



Oh well more work.