olethalb's white R-line bora - schmidts + air ride fitted.

mini update of what i've done so far today....

it's been on the to do list for quite a while now, so now the engine's out i thought this was the best time to do the chassis notch.

here's how it looks standard with the little rusty patch from where the shaft had been rubbing

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wire brushed it back

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and knocked up a template from an old section of exhaust

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then chopped out a notch from the chassis using the template

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once i was happy with the shape i obviously needed a more substantial bit of metal to fill the notch with so knocked this bit up

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then i tacked it in place

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i then ran a seam round the whole thing and ground the welds back

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gave it another quick brushing up with the wire brush so i could apply this

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so on it went

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then i thought i'd quickly try the shaft in the slot while i was waiting for the seam sealer to dry

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gave it another clean up round the area and threw some paint on

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the only other thing i managed to get done was a very quick clean of the engine bay

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Olly

managed to miss your comment dirtydubber, there was a few bits i wanted to do and got a bit carried away with it.

Always the way mate always the way. If i had a pound for everytime i heard that well you know the rest. Its looking great mate if your going to do something you might as well do proper keep up the good work oh and the up dates to go with um

yea you know how it goes, one thing leads to another and before you know it you're doing twice as much work as you intended.

not real progress but yesterday i dropped the subframe after work and then it rained so i downed tools for the day.

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today i got home from work and a parcel had arrived for me -

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my R32 rack, got it off ebay for £105 - stated to be R32 60k rack, i wasn't sure but when it arrived it looked to be a from a low miler so i slung a knuckle on the spline and checked it had 2.5 turns lock to lock and it did []

compared to my original rack

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so i cleaned the subframe, removed the lower arms and arb and fitted the rack to the subframe

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thats all at the mo

Thats guna be low if your having to notch the railes lol

looking very good mate, is the box section across the front of your subframe standard or something you fitted? wondered if it improved the handling at all

glbootboy - i won't be going much lower but it's good to have a bit of clearence.

jedi16v - thanks mate, thats a lower strut brace off an s3, i fitted it along with the s3 upper brace and did wonders for the boat handling of the bora.

how low is your bora now??? i got mine on 120mm drop all round on the coilovers and it scrapped everywhere, ive put back standard for the time being but its going back low for the shows.

not sure how low, i'd guestimate 60 - 70mm so not too bad.

didn't manage to get much done yesterday apart from painting my wishbones, today i got a few more bits started

these arrived

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so i fitted the ARB back on to the subframe

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refitted my wishbones

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i also ordered new track rods and ends to fit onto the R32 rack so set about stripping the old ones off

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then gave the bay a 'final' clean

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i also gave the block a lick of paint, not sure on the colour but ut's better than rust for now [:DD]

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unfortunately my new rods and ends didn't arrive today as planned but i won't go into that, so instead of fitting up the subframe i got on with a couple of other little jobs

first i trimmed the lambda loom down as the lambda is mounted near the manifold with the k04 and i'd just rerouted the original loom first time round. next i removed the plastic bits next to the master cylinder and taped the loom up.

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i then set about re-routing the fuel lines so decided where they were going to go and drilled (easier said than done) holes in the base of the engine mount

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then put a bit of paint on the hole edges

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to keep the fuel lines together i slid some heavy duty shrink wrap over them and heated it up

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then i routed them where i wanted them to go and put some rubber grommets round the lines to protect them and trial fitted the clip on elbows

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with mount

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and header tank

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Don't suppose you know the part no.s sounds like their just what the bora needs

Thats one really nice bora, are those cromed up C-class amg wheels?

jedi16v -

S3 lower brace 8N0 199 403 B
riv/cap nut N90 810 601 x 2
Screw/bolt N10 417 601 x2
washers N90 477 301 x2

Audi S3 upper strutbrace
8L9 805 629 A

Tim - thanks bud, they're mirror polished CL's bud but they're for sale now

Cheers bud looking forward to seeing it built back up

no probs jedi - me too mate

not alot of progress but my new rods and ends arrived from ECP finally yesterday.

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compared to R32 items i removed

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fitted the rods

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measured each side to get the rack central

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slid the boot on

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and tightened up the clips

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then fitted the lock nut

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and track rod end

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then i mounted up the subframe to the body

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today i didn't get alot done which was frustrating, mainly little bits here and there

my superpro dogbone bushes arrived

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so i cleaned up the dogbone and fitted the bushes up

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with the k04 down pipe running close to the rack i decided i need some extra heat shielding so i dug out some adhesive heat reflective fiberglass tape

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and put some around the rubber between the rack and the body

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then some shielding around the p/s har pipe on the rack and a strip of tape across the top of the rack

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that's obviously not enough so knocked up a little heatshield but haven't got a proper pic of it somehow.

while i was doing that i got another package from ibanezDan - top bloke [Y]

it was a 6 speed clutch line to replace my 5 speed item

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fitted

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5 speed line removed

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after my last pair of track rod ends turned to red rust after 6 months i decided to give these ones a coat of gloss black

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also cleaned a few engine parts

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painted the alternator mount, cleaned the p/s pump and refitted both, also fitted the crank / knock sensors

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i also cut down the plate between the engine and box as the rerouted loom will be going across it now.

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need to get a cambelt kit and water pump - (with METAL impeller) now amongst other things...

small update today with alot of pics though

got some bits from GSF earlier - supposed to be a cambelt kit and water pump but they had to get the other bits in. also got the much anticipated CLEAN header tank, oil filter and new thermostat.

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i started by fitting the thermostat

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and seal

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and housing

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i stripped the cambelt etc off the side of the engine ready for the new bits making sure i lined up the timing marks first

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while i was waiting for GSF to drop off the other bits i cleaned the bottom covers and painted the oil cooler plate

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sanded the seat for the waterpump seal

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pic of the old pump with plasic impeller - nothing wrong with it but bound to fail sooner or later

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then GSF dropped off my other bits - new pump with METAL impeller

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so i fitted the belt up

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refitted the bottom covers and pulley and marked the timing marks with white paint

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then refitted the top cover and mount

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Are you a mechanic by trade? Because you have a very methodical way of working. Top work chap, watching with interest .

thanks bud, i used to be a full time spanner man but gave it up a few years back, now i just do work for my mates and some private work at the weekends.

Ah thought as much, again great progress tread any plans to up the power?

it should be pushing around the 270bhp region and i'm getting the turbo recon'd and getting hybrid treatment while it's there - they say it'll be around 330bhp but i personally think 300 would even be optimistic, tbh 270 is wasted mostly without an LSD so that is on my to do list hopefully by the end of the year.

didn't get alot done today at all - what i did manage to get was a lupo power steering tank and mounting bracket from the scrappy, i've been looking into the possibility of relocating the tank a bit more out of the way.

it started to rain so i went down the shed and assembled my oil distribution block with the cooler plate and fitted it up with a fresh filter

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the rain eased off for a little while so i marked up where i wanted the p/s tank to sit and modified the bracket (still needs finishing)

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once that was about right i opened the hole up where the base of the washer bottle sat and filed it to size

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then it started raining again so i called it a day.

weekends are rarely ever a time i get to work on my own car due to being too busy working on other peoples, this weekend is much the same. weather is mainly to blame for the lack of work today.

i tidied up the hole for the p/s tank

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finished off and painted the bracket and bolted it up to the chassis leg

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got my discs mounted up and the brackets for the porscheys

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unfortunately the spacers for the bigger discs are too thick so will need to be machined down a mm or two

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i originally intended to paint the casing of the alternator but when i started to clean it up with a wire bush attatchment on the drill i decided to leave it at that, so i mounted it up and refitted the tensioner and belt

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Looking clean and unfussy. Have you done anything to the internals or are they stock?

Looking good still keep up with the hardwork. Have you put a dead line of what show to get it done or wen you want it done by?

dirtydubber - the internals are stock, it was on the list but tbh £££ is becoming an issue. 300bhp is still considered 'safe' for the AUM block although i'd rather have uprated the pistons and rods for peace of mind but i guess that'll wait 'til next year now.

thanks glbootboy - i want it back n the road at least by the end of july so i can run it through august and get to edition in september.