Audi A4 BAT - Quattro Project by Tom's Garage

[mgpdoc]

Gave the car a good wash after all the heavy rain these days in Athens









Next on the Fuel list is the fabrication of the Water/Meth Tank by Tom, and then after the installation of these on the Fuel Cell







Welding them pipes from the filler necks to the tanks. Let's see, it will be interesting I think

Cheers

And

Ordered this . . .

http://www.autometer.com/cat_gaugedetail.aspx?gid=3742&sid=67

Along with this

http://www.autometer.com/cat_accessoriesdetail.aspx?vid=130

Cant wait to get them.

Cheers

[mgpdoc]

Did some shopping today from Dazzle Showcar Promotions. . .



Let's take a closer look . . .

DAS6 Pro Dual Action Polisher
Great features:
Variable 6 Speed Dial: 2,500 to 6,500rpm
Weight - 2.3kg
Supplied with two Velcro Backing Plates Size: 125mm ( 5" )and 150mm(6")
Perfect for 5", 5.5", 6" and 6.5" polishing pads
Heavy Duty 850w Motor
D-Handle
Aluminium Gear Housing Cover
CNC Finished Gears








Chemical Guys Hex-Logic Pads (cutting, polishing, finishing)



EZ~ GLAZE with Acrylic Shine II



And some Megs Pads

[mgpdoc]

So, I bought some new hardware to make some more tests . . .



Starting installing them . . .



Almost halfway



There we are







Like it much more this way, than the first bolts.



Cheers

[mgpdoc]

So, I tried to start installing them filler necks . . .

First of all I had the task of removing the oem window . . .

Removed the wrapped oem trim first







Then I had to remove the window which comes together with the rubber strip. I tried heating it, I tried for a lot of time - I promise.

The window would come out for sure . . . I just didnt know in how many pieces that would happen . . . LoL

At least it was nice to take photos



And out it was



Along with the rubber strip, for good . . .

I then made a template out of carton, to see what I needed



Copied it on the plexiglas, dremel was slow, so I did the job perfectly with the angle grinder



Test fitting, seemed good





Time for some designing and drilling



One done



Test fitting AEM filler neck



and then both





Seemed pretty good on the outside, and on the inside





Then I had to drill them holes for the caps to be bolted and for the whole thing to be bolted onto the car.

Lets say this pic is of the third attempt of one made



The reason is that plexiglass has no tolerances and flexibility and does not particularly like to be drilled here and there. So it cracked the first two times.

Third time lucky then . . .



And everything sat like I wanted it to . .



Or . . . NOT . . .



This happened almost half an hour after I installed it in great shape.

Seems like this wouldnt work, and I had to change my material of choice.

So my other ones in mind were,

-Lexan
-Carbon Fiber
-good old aluminum.

So I went with the third, given it is a weekend and I needed to fix it asap.

So off I started





Starting to take shape . . .



Decided to go for black paint, to look more subtle - custom paint booth - lol



Secured in place





I decided to go for black painted bolts to not stand out - I will propably buy OEM ones, with Torx head - or black hex hardware - something in black either way



Time to install it





Left it like this for tonight . . . more to come in this project -



Cheers

[mgpdoc]

Did some tests with these . . .



Everything works great



And fits as it should





More to come . . .

[mgpdoc]

So today, was the day to do some more fabrication for our project.

Same location . . .









Same suspects . . .





Started to work on the first piece of the day





Starting to take shape - notice the smoother edge







Then worked on the other side of it



More adjustments



Hmmm . . . seems a cap was born for the AEM Filler Neck



Added the suitable o-ring





I think it looks pretty clean yet really nice - like we wanted it



Time for more



Started on the bigger car, the one for the Fuel Cell Filler Neck



make it light



Working on the finish





Time for some grip and some design







Place for the o-ring to sit on the cap's neck



Me Likey





Did some more adjustments to the fuel cell flanges







With o-ring fitted



Then, back to them filler necks - they have to be secured them caps, somehow, dont they - otherwise anyone can either steal them, or even worse, open the cap and put whatever he pleases inside it - not good . . .

So . . .



Here is an easy solution, with no external access, and no use of locks



Put some new bolts . .



Dont know if I will use those, or maybe go custom on those as well



Hope you liked this update as much as we did.
A big thanks to Thanos as always for his help and for the fun we had today fabricating these nice pieces

Cheers

[mgpdoc]

The level of work on this vehicle is outstanding! Clean car brotha!

Thanks a lot my friend

[Queef|Chief]

The level of work on this vehicle is outstanding! Clean car brotha!

[mgpdoc]

Ι really cant stop staring at them . . .



I dont even want to install them . . . .



We had so much fun that night. Tom had some fresh files for my car and some surprises . . .



Let's just say I love the rev limiter > 8500rpm - hehe

But then again, it is not so much fun watching the needle stop @ 8000rpm and the car pull like crazy, so, I think I might be in for something like this . .



And when lights are on at night



Of course it wont be put like that somewhere thrown in the dash. No. If one should be bought, it will be put in a custom panel we will design, with the shift light not necessarily in this position. I have already shown a custom gauge panel Tom designed.

We shall see

Cheers

[mgpdoc]

So where were we. . . . Oh yes.

Today, I had some time to do some work - my friend Thanos did most of it, in his machine shop.





It all started with some pieces of aluminum I had bought some days ago.



Here we go. First thing was to start doing the flanges for the rear side windows for the fuel and WMI tanks.





Love this material







Vag Group Tools - no **** - LoL



Measuring twice - cut once



Now we're getting somewhere



Wasted . . . oh well . . .



Usual tricks for less marks



Polishing



Time to drill the hole for the fuel cap



Let's not get lazy now, shall we . . .



Getting there . . .







Then it was time for the smaller filler flange, the one for the AEM WMI tank.

Same pattern, different sizes





Love this shape





And now we have two . . .





Time to move to other weapons of choice to make the bolt patterns happen







Tom was there playing too . . . LoL



Feeling the love



Almost ready





Ready





All they need is some cleaning when we are done with everything else - hehe

Now we also designed to do two flanges for my fuel tank, where the aluminum piping will fit into. Cause it cant be combined with my current plastic one . . .So . .

Time to start working on this as well





Lower one is almost ready



Drilled in the 12-bolt pattern of the Fuel Cell



Lower one will go in the interior of the tank looking like this





And the upper one, where the piping will come into . . .



So, what is left, is to do the two caps for the filler necks and some more details here and there. Then it is time for welding pipes from them flanges to the tanks.

Again, my friend Thanos will take care of the machining work, whom I thank very much, for all his help - once again :thumb::thumb:



Stay tuned for more.

[ItsaCorolla]

Nice car, but everything looks very busy. Sort of a big departure from the clean, uber simple look most people go for. I guess it's cool to see a little more function over form, rather than the other way around. I still prefer the opposite, or both if possible.

[mgpdoc]

Just a pic of my second blue A4 B7



An engine shot



And an interior photo, shot by Kostas Sant, and featured again somewhere on the net

[mgpdoc]

So today I got into buying some material to play with and start fabricating. I also received some orders. So here goes . . .











You can see my AEM W/M Kit, Kostas' Aem filter and hoses, and some raw aluminium cylinders to make the products we want. Pipes, hoses, and some new accesories for the compressor in my garage



Plexiglas to replace my rear windows











Sure you all familiar with the pump. Plastic AEM tank propably wont be used - let's just say that



And some drawings Tom has started doing . . .

[mgpdoc]

hehe, yes, and I want moooooooore . . .

Stay tuned cause there is a lot coming . . .

like super wide wheels . . . like widebody . . . like cage . . . like . . . who knows what else . . . LoL

[loekaaz]

So THAT'S where the European help-funds end up....

hahaha nice ride man!