Audi A4 BAT - Quattro Project by Tom's Garage

[mgpdoc]

So, more updates.

Today I thought it was time to tackle the task of installing the rear AeroCatch pins - and remove all OEM locking mechanisms.

My heart hurt a bit when cutting material . . .



Here is the material removed...



Making tabs for the interior hinge parts





Almost there -



And done







Pretty happy with the looks of it - functionality of it, plus the weight removal. I wonder if I can remove some weight from the arms that support it. We will see.

Here is the pic of what was removed

[mgpdoc]

Now where was I . . . .

Some first test-fits and mock-ups of the cap made for the wg pipe for when the car is parked in the rain . Rarely, but can happen.









Not finished yet . . . even though it is functional.

Oh, and some things ready to be shipped to me . . . and some more not shown . . .



I like my fluids fresh . . .

[mgpdoc]

Mmmmm...I smell fabrication . . .



So - work updates.

I needed to make the numbers Tom had ordered - happen



So with the help of my friend Thanos , who has two of the best workshops of this kind in Athens, we did it on our own, while the shop was open only for us, hehe

I just love these places - pure art can take place in here . . .



We first needed to make the wall of the future plenum thinner -



And then make some end caps on both sides from the square plates, which we did . . .

Hmmmmm....

Random pic - nothing familiar in the placement of things . . .

[mgpdoc]

So, managed to get some time to work on the IM project, with Tom and Thanos that helped a lot this time as well.

So I will let the pics do the talking . . .

Bought some raw material . . .



Remember the spare AEB IM I had bought some months ago - and told you it would be used for something . . . well time was now . .



Ready to be sacrificed . . . . RIP AEB IM . . .



Hehe . . .

Then we started working on the adapter plate to combine the new plenum with the .:R32 Throttle body. It could be done otherwise with a lot of cutting and welding - but Tom wanted to make a shape that would require the least welding when time came . . .

So . . . hole first . .



Then bigger . . .



More measurements . . .



Then M6 holes done. . .



Then the tricky part - Tom and Thanos figured out the way to do exactly what Tom wanted -



Here is a video of the procedure . . .

[ame="http://www.youtube.com/watch?v=zDu0mCfA9xA"]Throttle Body Plate - YouTube[/ame]

Resulting in this (not yet finished)



Bolted



Checking -



Yummy . . .



Mock-up of next things to come . . .





Ok Tom is sick of me taking pics . . .I can tell. . . .

[mgpdoc]

So more work was done today on the manifold process . . .

Pics to explain better . . .

We first made a ring on the TB flange , for the OEM .:R32 rubber gasket to sit in, as it does in oem manifold.







I really loved how it was done - perfect finish and quality overall I think . . .





Then, it was time for the plate for the IAT to sit in . . .



And then, a new one for the map sensor - for when the IC pipes are replaced by aluminium ones along with the IM installation .







And then - to call it a day - we drilled the hole for the throttle body.



Drill it first . . .



And then . . .





Came out pretty . . . . perfect , thanks Thanos so it so easy to weld now . . .



we did by the boring- method as shown in the video

[ame="http://www.youtube.com/watch?v=VqW2Ypzmbt8"]Boring-Machining - YouTube[/ame]

[mgpdoc]

Now you see, where this is going . . .

Some more pics. . .





More work done - mock-up - trying to see where it will sit - new coolant tank location - vacuum station, etc etc . . .

Photos . .

Decisions . . decisions . . .



Hello AEB head . . .



Bye Bye AEB Manifold . . . This one will go for sale I guess . . .



Well AeroCatch hood pins , can have more uses than what you think . . . hoho . . .



Took bumper off to remove the IC pipes which will be redone in Aluminum as well.



Let's throw the IM on . . .





It fits, and it clears the alternator as well.

Work bigger or smaller is needed on several smallparts - ie coolant tank - vacuum station, tabs for them, new hoses, new pipes etc etc. We will also modify the coolant pipe that goes over the IM.

Also this will be used at last - but with some different fittings to suit my setup



I also modified the coolant tank a bit . . .

Watch the tabs . Now you see 'em . . .



Now you dont . . .



And a photo I liked , work at the garage at midnight - Cheers !

[mgpdoc]

Updates -

Intake Manifold is sent for welding, since we dont have an aluminium welder - just yet.

Pics of some parts that were collected in the past two days . . .





Made some adjustments to the vacuum station with some block-offs



Remember the first prototype of the dump tube protection ?

Well it got a bit more love and work by Thanos













Seems interesting doesnt it . . .

Here's what did I use to make my pump a bit quiet, here are the pics I have







And, I also received these



YEAAAAAAAAAH

[mgpdoc]

Ok, so, I managed to find some time after work, and do some work with Thanos on the piece of metal I showed you . . .

So started working on it . . .



More . . .



And then some more . . .



Some more drilling and bolt pattern making - with the help of Fanta Orange Drink there, hehe



Come on Thanos - do work - stop fooling around



Then back on the machining process to work on the upper part of it . . .



Pretty obvious by now how it will look now . . . Or isnt it . . .



Awesome finish, just like I wanted it - simple - pure metal aluminium finish - art





And then made something else - the thing that keeps the alcantara shift boot in place - I already had one in black - but wanted one in same finish . . . so . . .



There you have them . . . .



Finished products . . .





Very soon on the car when I do something I need to the gear stick

Thanks again Thanos for the great day , hehe

[mgpdoc]

Time to show you guys the final product look of this -











Bolted the boot adapter



And there we have it









I really enjoyed this one, both the process, and the final result . . . really loved it

[mgpdoc]

I was patient to wait for the shop to make the welding to the IM.

So here are some pics.





Finished welding













And removed the injector holes to paint them.

Used this method





Now, I havent yet decided what colour to go with and what finish. I was about to re-do the colour in Audi Lava-grey. However, I really like the fab-look, the welding and all, and I was thinking to polish this. Either in a shop, or by myself. Leaning towards the polish . . . What do you think ?

Also here is a pic of the first IC pipe that is ready in Alu instead of SS - at last (less front end weight- lower temp)



On another note - I bought this to charge my battery due to the car not working for some days now - and me -stupid - forgetting to disconnect it



Then when I had some free time - and nothing to do on the car, I remembered this



Then saw this



And then I did it myself - even though in the B7 the difference is much of one to see , they are almost the same from factory





They came out awesome , all-red in person, and I will try it on a B6 pretty soon as well to see how it will look.

Also bought some new material . . .



Cause you know me . . I always have some new ideas . . .





That's it for now, going to the garage to see what I will do with the IM finish . . .

[mgpdoc]

So I decided to go for a fabricated - raw aluminium look - so we started sanding - boy a pain in the ass . . . but it pays off eventually . . .

Some teasers pics for now, as I have little time to upload pics at the moment



Turbo to IC pipe - painted by me, I really like how it turned out , plus going all black hoses - no more blue ones



More testing and prepping



Coolant pipe is being modified a lot and propably painted as well. Not sure on colours yet, but propably Kawasaki green for the pipe.

A pic of the hot side of the IC fitted



More to come.

Cheers

[mgpdoc]

Did some more work on the car with Tom. . . .

Painted the IM injectors caps / adapters



And some more



Problem with water pipe - and the solution on the left - but with lighter materials, again aluminium for the win



A mock-up Tom made



Almost ready to be welded



Made a bracket for the Vacuum Station







Ehhhhhmmmm..I guess Tom is thinking when will he stop doing **** on this car . . . .



Then he had the idea of removing the unused bracket of the oem coolant tank .

So I did, hehe



Will be painting this



Oh and this ESP/ABS unit bracket - useless and quite heavy (pain in the ass to remove though . . . ) - bye bye



More testing . . .



Fuel Rail on to check clearance



Getting there . . .

[mgpdoc]

So, it was time to installed the fabricated parts and for the pieces to come together . . .

New custom water pipe, fitted below the Intake manifold . . .



Pic of FULL-RACE vacuum station



Car started at 01.00 am, hehe, and it was ready to go to the shop the next day for the IC to TB pipe.



There it was, first thing in the morning,



Pipe all ready, REALLY light compared to my previous, and shorter one . . .





This had the same treatment as the other pipe - primed first with ETCH alu primer



And then painted in flat black



And this time, I had my Bov exactly where I wanted it to be . . .



Installed . . .



And the engine bay as it stands at the moment . . .



Better than it has ever been in my opinion, in terms of compoments installed, looks, and unnecessary things removed.

Cheers

[mgpdoc]

So another small update on an issue I wanted to sort out for a long time since I had the CF hood.
Something to keep it on. Yes I had a hing made, however it was pretty heavy for my needs.

So with the friend of my friend Thanos once again, we fabricated something small, yet suitable to get the job done . . .





Fits like this . . .





Even one can keep the hood, since it is only 4-5kgs, but we made two, to be sure.

And voila, hood seems to be magically kept open



And a pic of the car. She is mad.

[mgpdoc]

So, back to the fabricating part I had left behind. Went to the shop with Thanos and made the quick-release bumper fasteners we had planned.



Initial design - and final design next to each other



O-rings I ordered to my specs





Started making more







And yet more, hahaha



And then,gave them the look and finish we wanted



After that, we set to making it accept the bolt we wanted, making it flush . .



Like this . . .





I think it will look awesome. Especially painted in black and with the bolt making the right contrast. Made for both front and rear bumper.

If anyone wants some of those, let me know.

Oh, and I ordered a set of these as well to test some more things on my car.



The kit we made for me is ready to be fitted to my bumpers . . .



And then I painted all of them in satin black, they came out great.

Just some quick pics to show how it will fit . . .





Now I needed to find some time to fit them properly.

Cheers - plenty to come . . .