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Project B5 RS4 Sedan...

Discussion in 'The Project Room' started by Siena, Nov 26, 2007.

  1. Siena
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    Siena Active Member

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    [Nov 26, 2007]
    Hi guys,

    Been doing a bit of work on my B5 A4 quattro. She's currently in the bodyshop, under the knife, having a colour change, as well as brand new B5 RS4 panels / bumpers / headlamps and more being fitted. I have a highly modified S4 Biturbo, that exceeds RS4 spec, as well as an S4 6 speed tranny (DSY) to fit, but too cold to attempt that right now. Come spring, I'll be fitting the lot. Pictures from the bodyshop will follow soon. So far...

    As bought for the princely sum of £500, a '96 A4 2.6 Quattro Sport with her fair share of battle scars...

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    #1
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  3. Siena
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    Siena Active Member

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    [Nov 26, 2007]
    I wanted the RS4 body, to match the engine that was destined to sit between her chassis rails, but afte waiting in vain for used panels to turn up, I gave up, and went for new. I was probably just too bloody impatient, but hey, it happens!

    I began ordering parts from Ipswich Audi, and gradually stockpiled these goodies...

    B5 RS4 front wings...
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    #2
  4. Siena
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    Siena Active Member

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    [Nov 26, 2007]
    Swiftly followed by rear quarters...
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    And rear doors...
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    Rear quarters and rear doors...
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    #3
  5. Siena
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    Siena Active Member

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    [Nov 26, 2007]
    RS4 front bumper was next on list...
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    #4
  6. Siena
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    Siena Active Member

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    [Nov 26, 2007]
    RS4 front bumper needed these, so...

    RS4 lower grilles...
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    And RS4 foglamps...
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    #5
  7. Siena
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    Siena Active Member

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    [Nov 26, 2007]
    RS4 front grille...
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    ...And headlamp washer covers...
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    #6
  8. Siena
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    Siena Active Member

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    [Nov 26, 2007]
    By now, costs were mounting pretty quick, but what the heck!

    I ordered the B5 S4 Euro rear bumper, didn't like the look of a modified RS4 rear bumper on a sedan...
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    #7
  9. Layerz
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    Layerz Member

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    [Nov 26, 2007]
    Nice project, if you dont mind my asking what is the total projected spend on this project?
    #8
  10. Randomjim
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    Randomjim Active Member

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    [Nov 26, 2007]
    Some nice bits there, can't wait to see it all done.
    #9
  11. Siena
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    Siena Active Member

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    [Nov 26, 2007]
    I then ordered B5 RS4 side skirts...
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    I guess I could have used the original A4 front bumper mounts, and used a million washers to space them out, but I'd decided, no expense was going to be spared, so...
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    B5 RS4 rear inner arch rear tubs / liners were needed, so these turned up (by now, I was on first name terms with everyone at Ipswich Audi, including the Dealer Principle)...

    B5 RS4 near side rear wheel arch tub...
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    B5 RS4 off side rear wheel arch tub...
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    Followed by B5 RS4 plastic wheel arch liners...

    B5 RS4 rears...
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    B5 RS4 fronts...
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    #10
  12. Blue_Thunder
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    Blue_Thunder Active Member

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    [Nov 26, 2007]
    If you have a highly modified S4, why didn't you just change the bodywork on that? I've considered it myself, especially when I saw the awesome (but fairly pointless) job a mate had done on an avant RS4 conversion.
    #11
  13. Road Razor
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    Road Razor Member

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    [Nov 26, 2007]
    Looks cool. Look forward to seeing the finished project. Have you decided what paint colour to have?
    #12
  14. Siena
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    Siena Active Member

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    [Nov 26, 2007]
    I deliberated on purchasing B5 S4 chrome mirror covers, but in the end, went for a sexy set of B5 RS4 cast aluminium mirrors, complete with motors, and I thought I'd transfer my original glass over. But, the shape and profile are different, so have ordered the RS4 glass, be here by Wednesday. Still, RS4 aluminium matt cast housings...
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    #13
  15. Siena
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    Siena Active Member

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    [Nov 26, 2007]
    The highly modified S4 I'm referring to is just the engine.
    #14
  16. Siena
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    Siena Active Member

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    [Nov 26, 2007]
    B5 A4 2000-spec bootlid, the first of only 3 used parts used...
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    Sent the bootlid off for some modifications, to make it more up to date, as in B6 A4, and most other current Audis...
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    #15
  17. Siena
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    Siena Active Member

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    [Nov 26, 2007]
    The other 2 of 3 used parts for this project. B5 RS4 fron doors only differ from facelift B5 A4, in that they lack the rubbing strips, and lower trims. Bodyshop is welding up the 2 rubbing strip holes, and grinding off the lower trim studs...
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    #16
  18. Randomjim
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    Randomjim Active Member

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    [Nov 26, 2007]
    Like that bootlid :icon_thumright:
    #17
  19. Siena
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    Siena Active Member

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    [Nov 26, 2007]
    Then B5 RS4 Xenon headlamps...
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    B5 A4 2000-spec rear lamp clusters...
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    ...And matching bulb holders...
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    #18
  20. Markey
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    Markey Active Member

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    [Nov 26, 2007]
    Looking very good there mate :) loads of very nice parts there :) so whats the engine pushing out ?
    #19
  21. Siena
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    Siena Active Member

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    [Nov 26, 2007]
    You'd think for what the off side rear quarter cost, Audi would chuck in the petrol filler flap, but no. Full whack, less my trade discount...
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    #20
  22. Siena
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    Siena Active Member

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    [Nov 26, 2007]
    Still, Ipswich Audi had the grace to chuck in a set of Ipswich Audi licence plates, as well as a set of plate holders. The only gratis parts. Grrrrr....
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    #21
  23. Siena
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    Siena Active Member

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    [Nov 26, 2007]
    B5 RS4 front panel / radiator carrier...
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    #22
  24. Siena
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    Siena Active Member

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    [Nov 26, 2007]
    B5 RS4 side repeaters...
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    The B5 RS4 headlamp washer jets are lifted by water pressure, so I ordered the washer pump...
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    ...And B5 RS4 washer bottle...
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    Whilst looking round Ipswich Audi's forecourt, I decided I liked the look of the B7 A4 aero wiper blades, and matching arms, so...

    B7 A4 wiper arms...
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    B7 A4 wiper blades...
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    #23
  25. Siena
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    Siena Active Member

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    [Nov 26, 2007]
    I decided that, after 205,000 miles, the suspension must be shot. I purchased B5 RS4 Bilstein dampers all round, as well as Eibach springs, lowering the ride height by 30mm all round. I also took the precaution of purchasing all the front lower arms, as well as a full set of rear bushes.

    I fitted these on the 14th November, prior to her going into the bodyshop. Good thing too, near side rear had a broken spring. Both rear upper arm bushes were so rotten, the centres fell out, as I removed the through bolts.

    Bilstein dampers...
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    Eibach springs...
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    Front lower suspension arms...
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    Rear suspension bushes...
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    #24
  26. Siena
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    Siena Active Member

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    [Nov 26, 2007]
    A pair of 2003 MY Audi S8 Brembo front calipers came my way. As they are brand new, they naturally came with OE brake pads. I also purchased from the seller, a set of Hawk Performance pads, from the US. I've ordered a pair of B7 RS4 365x35mm discs...

    S8 Brembos...
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    Brembos and OE pads...
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    Hawk performance pads...
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    #25
  27. Siena
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    Siena Active Member

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    [Nov 26, 2007]
    Base engine...
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    #26
  28. jcb
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    jcb Active Member VCDS Map User

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    [Nov 26, 2007]
    does it have the RS4 Cosworth worked cylinder heads?
    #27
  29. Danielson
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    Danielson Member

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    [Nov 26, 2007]
    holy **** this thread is the nuts. its addictive as hell. i want more!
    #28
  30. Siena
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    Siena Active Member

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    [Nov 26, 2007]
    I looked round for suitable wheels for her, I have a set of RS4 replicas, in 8"x18", that need refurbishing. I wasn't really keen, as these wheels are on just about every VAG car, and the width was wrong. I'm getting them refurbed anyway, and will use them as winter wheels, with brand new 225/40ZR18 tires.

    I wanted BBS splits. The BBS LM's were going to be 6 weeks in coming to me, I wasn't happy with that. Then, I considered the fact they're 3-piece, so more chance of getting a tyre leaking.

    I ended up going for a set of 8.5"x18" BBS RXII's, (RX501's) shod in 255/35ZR18 Dunlop SP 9000's. These are a 2-piece rim. They arrived 7 days after ordering, and I was pleased with the service. They are ET32, but they were supplied with 12mm BBS hubcentric spacers, bringing the offset to a B5 RS4-friendly ET20. Matching bolts were supplied too...
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    BBS hubcentric spacers and matching bolts...
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    #29
  31. Siena
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    Siena Active Member

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    [Nov 26, 2007]
    Yes, it does. Courtesy of ebay.de
    #30
  32. Siena
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    Siena Active Member

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    [Nov 26, 2007]
    The next pictures will be from the bodyshop. I'll upload them as I get them. As I'm away for 2 weeks, from the 7th December, that may be some time. But, they'll be coming.
    #31
  33. Markey
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    Markey Active Member

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    [Nov 26, 2007]
    Its going to be a monster awesome project :)
    #32
  34. Randomjim
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    Randomjim Active Member

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    [Nov 26, 2007]
    Kinda like this one.....

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    #33
  35. Soupie69uk
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    Soupie69uk Owner

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    [Nov 26, 2007]
    Good god, you have been like a squirel gathering up all these bits.

    You must have spent a fortune but nice work.

    What colour you going to have the car painted?

    How was the bootlid done? A b6 and b5 combined?

    Thanks for sharing!
    #34
  36. Siena
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    Siena Active Member

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    [Nov 26, 2007]
    Colour is under wraps. Bootlid was done by having a metal plate folded and rolled, it then had to be carefully worked, as the B5 A4 bootlid is curved upwards each end. Took a whole morning to achieve.
    #35
  37. Soupie69uk
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    Soupie69uk Owner

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    [Nov 26, 2007]
    Looks good and least you got rid of the plinth that begins to bubble on the b5.
    #36
  38. Markey
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    Markey Active Member

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    [Nov 26, 2007]
    Well worth the effort though will look ace when painted.
    #37
  39. cliveh
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    cliveh quattro in the bones

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    [Nov 26, 2007]
    This is an absolutely awesome project!

    Be interesting to see how the total cost turns out compared to simply buying an RS4...not as much fun though...
    #38
  40. naefeart_A4
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    naefeart_A4 Bonkers

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    [Nov 26, 2007]
    All you guys with your projects, makes me want to join in ... aragh must resist... mrs will cut my b*lls off!

    Good work though Siena, really looking forward to more pics :icon_thumright:

    N
    #39
  41. Blue_Thunder
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    Blue_Thunder Active Member

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    [Nov 26, 2007]
    You know what this thread reminds me of? A lego set.
    You should number the parts and do a step by step guide of how to put it all together :)

    Are you doing the interior, ie: Dials, centre console, etc.?
    #40

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