The one...

[Dub Toffee]

Hi mate got your pm thought I might reply here for everybody's benefit as well.

THE and i mean THE quickest way to approach this would be to Build a Chassis Jig that is a mirror image of what is underneath
your donor vehicle, in your case an S3.
This option makes the most engineering sense as you will
without fail replicate exactly what Audi has done and everything will line up according to Audi's engineering.
If you need to shorten the wheel base front to rear, you can do that with a bit of smarts and still have a jig that is spot on.
The track width will however remain the same as the Audi.

Failing that option you can do what I did and design your own/modify a chassis.
This requires so much more time in measuring and lining things up it is ridiculous.
It is also to time consuming to recall all my measurements and designs… its a one off…
Doing it this way my build is up to 600 man hours easily!
I did it this way because in my motivations I wanted to "craft something"


In my opinion it would be far more cost effective and time efficient to buy yourself any cheap
crap body S3 that is still running good for 7k.
You then have everything you need to transplant over to the mk1 using a Chassis Jig that you built.
Once you have a mk1 with a functional 4 motion conversion only THEN consider what you want to
replace and upgrade… but at least for now you have a working 4-motion conversion.

The Jig will emulate all the pickup points for
-rear suspension and drivetrain
-tail shaft
-front subframe
-engine mounts
-suspension mounts


- Take your 4-motion donor vehicle...
-Remove all your suspension, drivetrain, engine etc, braces etc fuel tank etc...
- All you want to see is a completely bare floor pan and engine bay
- On your workshop floor Flip it on its side
- Adequately brace it so it doesn't fall over

-Now the fun begins...
-Locate all the mounting points for the rear and front drivetrain and suspension assembly.
-paint them pink with line marking paint so you don't miss any when building the Jig
-make plates 6mm thick appropriately sized to the mounting points
-bolt all the plates on wherever you marked the relevant chassis mounts

-At this point you are ready to connect everything with tube and brace it very well
-you will end up with a frame that perfectly mirrors all the pickup points for your conversion
-if you made it right you should be able to unbolt all your plates and the frame / Jig will seperate from the body of your donor car.
the jig will need to be be sturdy and stiff and NOT flex when it is removed.


NOW On THE MK1

-have the MK1 on a Rotisserie
-put the Jig up to the mk1 and start to look at where you need to cut metal away for all the mounting points to fit into the chassis
of the mk1
-simply build out the chassis of the mk1 to meet the plates bolted to the chassis jig use 3mm plate

you will probably need
-60h to finish the jig and shorten it to suit the mk1 wheel base
-200h to align the jig with the mk1 and finish welding all the pickup points
-150h for stuff ups and rework because … it happens

Here is HR pumping them out in this fashion not pretty but gets the job done
https://www.facebook.com/media/set/?...1793792&type=3
Its Obviously not for the faint hearted or time short, Looks like HR have had a few failed attempts come their way
to be redone professionally.

If using Tube on the Car...
ONLY use seamless tube bought from someone like Andrew Race Cars, his is arguably the best in Aus for quality,
get certificates for the metal you buy and use. Plate tho it doesn't matter

you will probably need to consider this build going for a few years and then what you will do to survive the
motivational mood swings haha mates are great their.
You could always just chase a decent job work lots of overtime and buy an R32 instead sometimes i wish i did that haha


Good Luck!

[Mk1@4Motion]

DAMNNNNNNNN, that is a mouth full. But I am also hoping to craft my own things. And I am hoping to try and use as much as possible tubing. Something similar to yours.

But thanks for all that, I will take it all in.


Only The Good Die Young 45

[sports racer]

Here's one I prepared earlier.


Mk1 Caddy, Quattro 4x4, BAM 1.8T - Readers Rides.... - Edition 38 Forums

This was built by transferring the Audi suspension pickup points to a frame and then to the Caddy.

[Mk1@4Motion]

Here's one I prepared earlier.


Mk1 Caddy, Quattro 4x4, BAM 1.8T - Readers Rides.... - Edition 38 Forums

This was built by transferring the Audi suspension pickup points to a frame and then to the Caddy.

I was looking at the exact same build a couple of days ago. I'll have to wait a little bit to see what is going to be best. I am looking at installing the engine and gearbox first thing and then I want to cut out the sparewheel well, and then start by building a frame to line the rear diff up. From there I will have to see what I am going to need to do.


Only The Good Die Young 45

[Dub Toffee]

And that is exactly how its done nice work finding that thread sports racer, I have not sen it yet
but isn't that the one HR did and was in PVW a while back?

Using tube does have the advantage of maintaining a reasonable track width but negotiate with an engineering signatory first.
If you showed an engineer how it has been done like the above I'm sure you won't have any dramas explaining you want to do the same thing but use tube.

Personally I really don't like the huge track width of the audi or Mk4 on the mk1.
As in the caddy that HR did.
The width is a bit out of proportion in my opinion.
I would much rather something closer fitting but still utilising wide tyres…
But if you shorten the track width you have the absolute mission of
modifying everything to suit and that just takes time… like a good wine haha

[Mk1@4Motion]

And that is exactly how its done nice work finding that thread sports racer, I have not sen it yet
but isn't that the one HR did and was in PVW a while back?

Using tube does have the advantage of maintaining a reasonable track width but negotiate with an engineering signatory first.
If you showed an engineer how it has been done like the above I'm sure you won't have any dramas explaining you want to do the same thing but use tube.

Personally I really don't like the huge track width of the audi or Mk4 on the mk1.
As in the caddy that HR did.
The width is a bit out of proportion in my opinion.
I would much rather something closer fitting but still utilising wide tyres…
But if you shorten the track width you have the absolute mission of
modifying everything to suit and that just takes time… like a good wine haha

I will have time to modify to make the width look good and not having to run wide arches etc. I am not trying to finish the build in a year. But thanks for the help from both of you.

I did speak to the local registry a couple of days ago and they emailed me a link with the paperwork I can read through to be able to follow their rules and have it done right first go.


Only The Good Die Young 45

[Mk1@4Motion]

I know this is a Mk4 R32 but DAMNNN it is a mighty fine bay. I hope I can achieve that level of clean.




Only The Good Die Young 45

[sports racer]

Just see Alex G to do your engine bay



the swallow tail project has begun.......

[dubstar]

This is how you add 4WD.........engineering at the next level (watch all 8 episodes)

https://www.youtube.com/watch?v=7hCPODjJO7s

[Mk1@4Motion]

So I poped around at Shadow_Rusty to drop of a few extra things he couldn't fit after swinging by yesterday.

I had a good look at the 2door and I have only a couple of things I have to sort out to have the body rust free(outside of surface rust) and also have it straight.

Niw I really can't wait to have this kick into high gear.

PS:
If there is still someone out there who might be interested in a few 4door parts. Send me a pm if you want to swing by and come and have a look.


Only The Good Die Young 45