My 91' Audi S2 (3b) project pearl grau

[n3c]

Lars - Audi S2 Pearl Grau 1991 (3b)

Since I already have a thread on s2forum im not gonna do a lot of write up just thought it might be fun to share my project with others.



It's an Audi S2 (3b) 1991 model coupé. Bought it quite cheap (cheap to be Norwegian price) and started working on it.
I put it together after installing all the parts I wanted then I found out it was more rusty than I knew about.

So everything is taken apart down to every bolt and built up from the ground.

So I will just share pictures right now since it tells more than thousand words

Im currently doing some work on the chassi before painting it, then engine will come in place.

- Lars

 

[n3c]

This was when I bought the car unseen

 

[n3c]

Headliner was sagging, rusty underneath, every component painted in an ugly orange color by previous owner.

 

[n3c]

Started fixing the car Verkline bushings for everything, every chassi part new, every bushing etc etc.
KW v3 coilovers, fixed propshaft bearing etc

 

[n3c]

Got new custom exhaust, 3" all the way with one muffler. fixed the headliner, bought some more parts, fixed some interior problems.
coupled up a stack turbo gauge in the center, fixed bushings on gearbox etc

 

[n3c]

Started stripping the car down, grinding it down, removing all rusts, bump and dents, welded anew part in the rear where its typical rust problems on these cars.
epoxy coating whole under, seam sealer and 3M 08800 underprotection.

Painted it all in the cars color (Audi pearl grau) looks black in pictures but its a "dark grey" / pearl grey.

 

[n3c]

 

[n3c]

Some more chassi job and seam sealer ..

 

[n3c]

Fitted brake lines, fuel lines, new brake booster kit with larger cylinder 27mm. going through electrical wiring / engine harness. changing out what is bad.
To my excitement the wires looks almost brand new (though copper is old but Ill hope it will hold for now..)
Also powdercoated some parts in the garage. seems to be holding up quite nice. Not bad for a real cheap powder coating kit.

 

[n3c]

Engine is out and sent for total rebuild, have to measure first before getting new pistons/rings etc. Got the basic parts laying around
Tried fitting the brake setup, re-done it several times now, never satisfied

 

[n3c]

So I've been struggling about what to use or not. I've got the original 5-speed with 220.000km on it, it seems fine not too bad, no whining,grinding etc.
But for higher power figures it might break straight away. it has some kilometers on it and I know for sure that it will go around 400hp anyway. But atm
my plan is running around 300-320bhp.

Got a 01E DQT from a Passat 2.5 tdi 4motion but I think the gearing is a bit off on the last gears. So I bought an 01E DSY from a S4 2.7tt B5.
Too bad I refinished the DQT box to good condition.

Also gonna mount a Coolerworx shifter to get some more precise shifting.

 

[n3c]

Status right now is, waiting for a bit warmer weather. Don't feel like spending $$ on electricity/diesel atm. its -17c and the garage is 130m2 ..
need around 18-20c to have decent working temperature for getting the chassi how I want it regarding paint etc.

Engine has been away for some months, someone is way too slow in the building process but I dont have any urge to nag about it now.

Going to fix up the last dent in the paint on rear right fender(it came after I Fixed it last time.. so not sure what has happened).


Hoping to do more work soon and update when painting is done going for original color which is Audi Pearl Grau / Pearl Grey.

- Lars

 

[spartacus68]

Impressive work so far. Good job.

 

[n3c]

Impressive work so far. Good job.

Thank you