Bobby Singh's Audi S2 avant project

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Great work Bobby
 
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Building oil pressure (Reaches 5 bar :) )


View: https://drive.google.com/open?id=1yw56WgzVGowkmKOaQxfdupy9vFPhEy3k&usp=drive_fs

Power steering pump bracket (supplied with the wagner)


View: https://drive.google.com/open?id=1FJOkqaCTZvyr1bhiwfzBX0-uYjkPUJM0&usp=drive_fs

The power steering bracket needed a lot of cutting to clear the BST manifold and also needed a shorter belt


View: https://drive.google.com/open?id=14I76CDz0APP5pg0lF0W3sjUprKhsk_15&usp=drive_fs

Custom ISV bracket with custom plumbing


View: https://drive.google.com/open?id=1MRl2eL4x9j8bUaFdE92zhfjMipuiOjsp&usp=drive_fs


View: https://drive.google.com/open?id=13zPB7mR9Ne7gbbdSl_dqupJy7Mt8kaSX&usp=drive_fs


View: https://drive.google.com/open?id=1SdzAq77GXjrozf18__l61tPbUf-EVGP8&usp=drive_fs


View: https://drive.google.com/open?id=1gvgyVjlPEXqsCHBD81ua42bU75k7Ew-I&usp=drive_fs

Rad pack

70mm Rad with 305mm fan


View: https://drive.google.com/open?id=1y0MpQ8_pQlaUqBVJIrFdlwvMIcbnQdQ2&usp=drive_fs


View: https://drive.google.com/open?id=17WoqdXWtuwZOvrz5zv3PNcpbssqjxM58&usp=drive_fs


View: https://drive.google.com/open?id=1vGNBp9Mykq2Yygz7Jwa87sfJ6kiIjh5S&usp=drive_fs


View: https://drive.google.com/open?id=13XTMeQA9jz9BRgHJW8m6hZS9OD-jRfQh&usp=drive_fs


Test fit:


View: https://drive.google.com/open?id=1jzDqmExUpiFonkJyBewvmcfdydGXEREt&usp=drive_fs

Fan mounted and period correct fan connector located with a custom bracket:


View: https://drive.google.com/open?id=1lzdBb1A6-q1UACFgqZP8mMfckhE5PfDY&usp=drive_fs


View: https://drive.google.com/open?id=1dr9K-Mrm9fEUe31T064gp0eH5o5bkd47&usp=drive_fs


View: https://drive.google.com/open?id=1632c0xxoUPdx45JRSR4l7J4Y0n3E0cbK&usp=drive_fs


View: https://drive.google.com/open?id=1vFz7gtiOCEx8vs28lXBWVgGw7uNKsTI5&usp=drive_fs

More powder coating


View: https://drive.google.com/open?id=1W6nybuOstPZ-WTwgcXKeokcLm4VPGFYj&usp=drive_fs

Rare alternator bolts sourced


View: https://drive.google.com/open?id=1CIHl8bKOLUxaHMWGNqDi_vpGPb5c756y&usp=drive_fs

Crank bolt tightening 450nm yep you heard that right 450nm!

Flywheel locking tool (custom made)


View: https://drive.google.com/open?id=1Ey1F33-s-bt9gzYZ531d463fNDSoDSfq&usp=drive_fs


View: https://drive.google.com/open?id=1QhndrF3Mt2SfycapdAUN5zQWD-mn9YqZ&usp=drive_fs


View: https://drive.google.com/open?id=1o2je3SQbAiX5ziaW2eo022adaJGMosIO&usp=drive_fs

Wiring extended for throttle position sensor & IAT


View: https://drive.google.com/open?id=1V0vBxgKiKSWqwX9srZOKVOJYZevUtel6&usp=drive_fs

Turbo mounted


Cheers
Bobby
 
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ECU wiring modified to allow additional 0-5v inputs, w/m trigger etc


View: https://drive.google.com/open?id=1FxaI2KuCRTstKsrA59xOzrc-1MjpUdVz&usp=drive_fs

Extra supports for the wagner intercooler


View: https://drive.google.com/open?id=1GLMdOI3HPvOAsEx-wAqqgxqe8DNOa9Na&usp=drive_fs


View: https://drive.google.com/open?id=1SFXX0DMshTfDXrtvBcmYNqJ6H3bkDuY2&usp=drive_fs


View: https://drive.google.com/open?id=1yWjYiTb43ST494arUe2eGFKGTDm1HuNA&usp=drive_fs

Rad support & bumper brackets modified:


View: https://drive.google.com/open?id=1EgFMLVCRDqHaVPhp5-4audgy3b3tjcbB&usp=drive_fs


View: https://drive.google.com/open?id=1s3xNbSmTkNc4iI1Wa4KZVeoE0LMq9JvJ&usp=drive_fs


View: https://drive.google.com/open?id=1qhtTdPuMbMd21q8qutorU81dNGHwrhFC&usp=drive_fs


View: https://drive.google.com/open?id=1zwbJHSBbxSbWHIQUiBTrhEYf196qR8wc&usp=drive_fs

Intercooler pipe work - nice cut down 63mm 90deg worked out very well:


View: https://drive.google.com/open?id=1aEGPsHBluWY55Jreltg1JXDvA_JMjqyR&usp=drive_fs

Bumper alignment


View: https://drive.google.com/open?id=1zuzVIUD5ir8zSAlEV-yTlUQOfZlsJqQO&usp=drive_fs


View: https://drive.google.com/open?id=1R5it2IfcUHy6mq0PSmUoMKDAAPHPaajQ&usp=drive_fs


View: https://drive.google.com/open?id=1JnJ4K1joIC7PDTlZR12vL9zf18b6DKQk&usp=drive_fs


View: https://drive.google.com/open?id=1nR6HTlM7Oy0mmEDk4VbWrjWX44mGqiai&usp=drive_fs
 
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Fuel leak

Seems the stock line have been rusting away under the OEM clamps

Stock ID is 6mm
I used 10mm OD (8mm ID) aluminium fuel lines
Managed to reuse the stock mounts & rubbers with some modifications


View: https://drive.google.com/open?id=1qKQ3mBOkn9z4LsOrp20p6uUpxblgD4uf&usp=drive_fs


View: https://drive.google.com/open?id=1I1sZPHQyYb1hnSKks4GhiBQt-Pg1IPDS&usp=drive_fs


View: https://drive.google.com/open?id=1BV4OMpB_vjqVp2RlsIMwRRf3f65RABbX&usp=drive_fs


View: https://drive.google.com/open?id=1A8w2nDQmLK1TUWeZTM_AkGO9i8tb0YgJ&usp=drive_fs


View: https://drive.google.com/open?id=1VQTFkY0QGe50iKeM27QDHqhs7CmutRNq&usp=drive_fs

OEM rubber mounts expanded


View: https://drive.google.com/open?id=1v7us9A3ZYcKpPpaMN1kpHcW14hKmVnhp&usp=drive_fs


View: https://drive.google.com/open?id=1e2nqz_HTDixctw1sQ_9vpk5xMWXTR4qg&usp=drive_fs


View: https://drive.google.com/open?id=1uNlenCfblVfW_PbnbRGBq5DMhxiMLR6c&usp=drive_fs


View: https://drive.google.com/open?id=14lxKua2xD36Ceab42jPsi0sKMWDrEHL8&usp=drive_fs


View: https://drive.google.com/open?id=1r2sGm_Gg_3EHfTkPbodOX0oOfqwhAxLD&usp=drive_fs
 
Exhaust work


View: https://drive.google.com/open?id=1X3yKoNv1-YmV8AvZkGr754v54uyRrMrA&usp=drive_fs


View: https://drive.google.com/open?id=16c0PqaZtBhyUCPNn3FL5ouOq14UDEete&usp=drive_fs


View: https://drive.google.com/open?id=11BIqeuhXNW_o_Cycdqy-cp-MMSsuKghP&usp=drive_fs


View: https://drive.google.com/open?id=1Pc0g-f34JgDNaJ6xgIPKS7VVUDogv98w&usp=drive_fs


View: https://drive.google.com/open?id=1D6qjYvGZsZXpOWrs89ohOc5AxeHBwFDG&usp=drive_fs


View: https://drive.google.com/open?id=1NOR2kfO6aF9xoBHX4Ky7QbFaiiOqYJlr&usp=drive_fs


View: https://drive.google.com/open?id=1g0IEQKUHCsd9Oaa1ir51ua_PWaTMgYUZ&usp=drive_fs


View: https://drive.google.com/open?id=14uNb1lZc5c9o0YjKI5OELmh4ssTo2EGs&usp=drive_fs

Mid section support using a R8 hanger


View: https://drive.google.com/open?id=1RiqCdgI-TlXzqsP6AyYvZVuK8MkQj9GJ&usp=drive_fs


View: https://drive.google.com/open?id=1afUVXLq90Ft5GxlODMGi1OcFGha4UVA6&usp=drive_fs


View: https://drive.google.com/open?id=11WPZmmKKf37CLubQ5OvfdkijcADHLTMJ&usp=drive_fs


View: https://drive.google.com/open?id=1dWliR96Fo8ZrcLESc2eSJkvqQXT0DazZ&usp=drive_fs


View: https://drive.google.com/open?id=1BQNrPEjEUIgHTQwYksvyB-1QuOkyr2Rb&usp=drive_fs
 
Exhaust got done with a additional muffler

Rad guard modified and installed:


View: https://drive.google.com/open?id=12gxNZx_L2QrdIJbGjfeENBXrqFukXa1g&usp=drive_fs

Couple of underside shots:


View: https://drive.google.com/open?id=1l-HgyiCb_fV4krHeSay-m2IeV1RyMh5n&usp=drive_fs


View: https://drive.google.com/open?id=1MqohwTSqLpjIWGTZ8l9VA4b-M15LlHae&usp=drive_fs

Exhaust manifold back pressure sensor bracket


View: https://drive.google.com/open?id=1gYMs03L_Opi9f0qnVnKvSLhVmnjjSm6x&usp=drive_fs

Coated & mounted


View: https://drive.google.com/open?id=10tlHvNnH32gOm6aZ0x6n6J_LK_nXmZ8u&usp=drive_fs

Discovered the new thermostat was stuck so fitted the old one back


View: https://drive.google.com/open?id=1A22gM11CqmoHWbsBPhwS4OzNtBYh8D6g&usp=drive_fs

Modified the oil pressure switch fitting to accepted a Mercedes 11 bar sensor from a diesel for oil pressure readings


View: https://drive.google.com/open?id=1RKd7nUTRbFxGQhxyi4SzqB7mBAZq8Jl8&usp=drive_fs


View: https://drive.google.com/open?id=1IY_PG-Kt0-6lETtVh8mcZCwvWJdOxUgS&usp=drive_fs


View: https://drive.google.com/open?id=1JDbWTMcIOAPNL0SEKwz5g4kD8udThdPo&usp=drive_fs
 
Set the timing for TDC in the ecu at 60deg and confirmed via timing gun:


View: https://drive.google.com/open?id=1fAFkhKauTDmjFrLGJsIWlij-o_IMF5KG&usp=drive_fs

Fresh S2 mats


View: https://drive.google.com/open?id=1dyqw1MqxyKdm1OQR0rm6hnKHYsrIEI3V&usp=drive_fs


View: https://drive.google.com/open?id=1j1IvlpU3VOQ9B66qZyH1u-SboKKbWtSc&usp=drive_fs

Noticed the front wheel were sitting too close towards the front doors - turns out all the aftermarket ball joints for the s2 have the wrong angle.
Ended up getting a pair of Audi items from Germany and now the wheels sit true


View: https://drive.google.com/open?id=19C97XgbwtEATS396S8_OvjSzzww-Yz0J&usp=drive_fs

Got the tracking done and the car now drives straight:


View: https://drive.google.com/open?id=1dOfflAIeu83S6aRMf30Ud3b-EJaxGLV5&usp=drive_fs

Custom forged wheels from China

So ended up getting some custom wheels made from China - they have the correct spec so fit without spacers or any other modifications
Forged 6061-T6
18" x 8J
ET 33
CB 57 PCD 5 x 112

I wanted a square set with max concave - after a lot of back forth with designs I went with a OEM plus wheel with 5 spokes to suit the 90's era


View: https://drive.google.com/open?id=14hPq6g4ZQIRa-pIF3oy_pCTnPx8oqf-x&usp=drive_fs


View: https://drive.google.com/open?id=1fKqtQ5giJ6QJKPL7pzcUXLkvrBTB4apJ&usp=drive_fs

All stickers refreshed:


View: https://drive.google.com/open?id=17W43UFIY5dIb-PzjUZ4vAKcgM4K2e4Wg&usp=drive_fs


View: https://drive.google.com/open?id=1lVaXAUTMoFvUZZGa3ebnP1KQtgSGpQOR&usp=drive_fs


View: https://drive.google.com/open?id=1drrB8B_QOOyRQi0-_8RwhSGi2x6ok675&usp=drive_fs


View: https://drive.google.com/open?id=1WxqmWyd5xH1wsn_qvB_cEemn-3NeiSzF&usp=drive_fs
 
 
Fuel rail issues with Asnu 1100cc injectors

So these injectors would not stop leaking plus I was having issues with using their XX O ring seals into the BST manifold.
After wasting days trying to seal the injectors it was decided to move away from their top hats and us top hats that use the C clip to hold them to the injector body & rail.
Also, it was noticed the fuel rail was not sitting true to the manifold and therefore pushing the top hats out. I didn't experience any issues EV14 injectors because they were made from one unit (no top hats to push out).

As the injectors came:


View: https://drive.google.com/open?id=1YrK_75AZ0u5i2pEyX__4HU4eKmDcIyIw&usp=drive_fs

Top hats


View: https://drive.google.com/open?id=145McoXsBKlkMKOrSq1K3QYw3nJzpN2jw&usp=drive_fs

Test fit into the rail


View: https://drive.google.com/open?id=1RkfkWnXq7jITQwajoXViJFiil09_t0im&usp=drive_fs


View: https://drive.google.com/open?id=1GHKwyz76pESJxmoMDkOLW8F28t_oJX_U&usp=drive_fs

Injector bore honing


View: https://drive.google.com/open?id=10ERXSrr8eLP7iKRIP4k04u5MWgnMDO3a&usp=drive_fs

Before


View: https://drive.google.com/open?id=1bg_AGpReBTjtGiG8XDn4oHiv8YHK1Gqi&usp=drive_fs

After


View: https://drive.google.com/open?id=1c3ovZ6QMzdmg1fCUKLhHtAFxs3w3C0ta&usp=drive_fs

Drilled and tapped the BST manifold with M6 threads


View: https://drive.google.com/open?id=1mw-NksGYcLXR8tfvmSh9j97q6y_Z07CH&usp=drive_fs

Got 20 x 20 x 65mm box section and had the centre machined


View: https://drive.google.com/open?id=1UBea0MYebP3sr_Qh1qneqSBiKKpje6WG&usp=drive_fs

Welded the box sections to the rail


View: https://drive.google.com/open?id=1_65n5RMWwqyTMyWBQdUFhzzzAULLGqpT&usp=drive_fs

To prevent any rotational stress on the rail a top support was added


View: https://drive.google.com/open?id=19kuASpzHdn4TNn9VutsrZiRI_qLFFqFF&usp=drive_fs

Tied it the cam cover bolt


View: https://drive.google.com/open?id=1-09_cQg9EcIxn3ma6t5E7hEvu2VGIO9F&usp=drive_fs

Rail finished


View: https://drive.google.com/open?id=10BCxNkL_0C0GB4qX3dKee97FS9m9-ICi&usp=drive_fs


View: https://drive.google.com/open?id=1H3uLH73Uc7bseMSLkwkwf_cIpb_ZLKaj&usp=drive_fs


View: https://drive.google.com/open?id=1MGf6iR7KMxnIkFb0ueac8UQXlFZxWB6v&usp=drive_fs

Installed
To get the connectors on I had to solder wiring on two injectors directly and then epoxy resin filled the connector hole


View: https://drive.google.com/open?id=1BRnsM0UbcVHy62nLVdR_emWE-Eel-jqk&usp=drive_fs

Cheers
 
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