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Discussion Starter #81
Finished the brake proportioning valve install. The factory Audi unit was leaking.
The new Wilwood (260-12627) valve fit nicely in the engine compartment.
This is one more item to check off the list. Less than 2 weeks to the Southern Ohio Forest Rally.





 

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Discussion Starter #82 (Edited)
Southern Ohio Forest Rally Update:
The event went very well for us. Car did great and we survived the roads and the heat in the car the first day.
Only real issue was a rear axle nut coming loose at the first service and a CV joint that was also coming loose, both were tightened at service and checked the rest of the weekend.
Also had a little run in with fence post during the very wet and muddy head to head super special. See the pictures for the dent.
The super special was fun. We raced head to head with the Audi 90 of Johansen and Little. They ended up getting 3rd in the national rally standing, I am not sure how long it has been since an Audi has been in the top three but I am sure it is has been many years.

Results for Friday Regional Rally 16th overall and 7th in the Open Light Class (46 regional cars)
Saturday Regional Rally Results 15th overall and 6th in the Open Light Class.
For the National Standings of the two days we were 18th overall and 4th in class (62 cars started), one place off the podium.
The roads were very tight and had a lot of tight corners with drops on the outside. We were happy with our speed and look forward to doing this event again.

Enjoy the pictures and videos.

Stayed at the Ravenwood Castle, Very nice place and close to the first day service.



















Well Done Paul and Susi


Super Special Damage




[video=youtube;Xe9bJhGJC_o]http://www.youtube.com/watch?v=Xe9bJhGJC_o[/video]

[video=youtube;5ejrsgCd0b4]http://www.youtube.com/watch?v=5ejrsgCd0b4[/video]

[video=youtube;KRkqlnXN1Ho]http://www.youtube.com/watch?v=KRkqlnXN1Ho[/video]

[video=youtube;CWht8H4iKR4]http://www.youtube.com/watch?v=CWht8H4iKR4[/video]

[video=youtube;-0kCqUvdXfw]http://www.youtube.com/watch?v=-0kCqUvdXfw[/video]

Well Done Paul and Susi, Putting an Audi on the Podium

[video=youtube;rVb-NhdqC1I]http://www.youtube.com/watch?v=rVb-NhdqC1I[/video]
 

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Discussion Starter #83
Show-Me Rally Update

Show-Me Rally update.
All went well at the 2017 Show-Me rally. No issues with the car at all. The weather was also great, had rain half way through the event that took the dust away and cooled the temperature down. We ended the event 5th in the Open Light class and 7th overall out of 24 cars. Comparing times from our last running of the event we were faster on each stage, so we are moving in the right direction. Check out the pictures and the videos, the spectator area was very good, the best we have looked at any spectator area yet. Thanks to Javad at 034 Motorsport for the push to go faster, we are working on it.
Enjoy.





















[video=youtube;sjSaWorvibk]http://www.youtube.com/watch?v=sjSaWorvibk[/video]

[video=youtube;1el5b1cailk]http://www.youtube.com/watch?v=1el5b1cailk[/video]

[video=youtube;mcbd7HLcJ0Q]http://www.youtube.com/watch?v=mcbd7HLcJ0Q[/video]
 

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Discussion Starter #84
Update on the Rally Car.
Installed a new fuel pressure regulator, the VP 109e does not play nice with rubber and the old regulator was starting to get eaten up.
Brake reservoir was leaking from the bottom grommets so I replaced them.
Also eliminated the rubber feed and return line from the fuel tank. There was always a smell of fuel under the car from the fuel making it out through the rubber lines. We will have Teflon lines from back to front now, -8an for the feed line and -6an for the return. The compression fitting for the feed line was an odd size, 12mm, but I found one online and my brother did some creative welding to a -8AN fitting. The return is a more standard 8mm and was easy to find.
100 Acre Wood is getting closer. Should have the tank back in this weekend and then I will see if it leaks.



Weight Saving (Remove all the rocks and dirt from the last 2 events, Some Missouri Rocks and Lots of Ohio MUD)






 

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Discussion Starter #85
Battery Box reinstalled. Fuel Tank is reinstalled and leak free. New Fuel Pump is installed. Working on replacing strut inserts and we should be ready to race.









 

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Discussion Starter #86 (Edited)
Update on the 2018 100 Acre Wood Rally.
Car did well and so did the drive and co-driver.
Finished Day 1 in 23 overall and 8th in class.
We noticed that we were feeling fast but our times were a little slower that what we knew we could run.
Day 2 went well, the Cattle Jump was good. Lost some time in the Huzzah SS, missed the turn into the woods
Finished Day 2 in 23 overall and 10th in class.
In the National Standings we finished 26th overall and 8th in class.
Had some fuel issues on the 2nd day. With the longer transits we ran short on fuel for the last loop of stages (we run VP 109E) and we had to fill up with 10 gallons of E85. Worked well but we did loose some power, but we finished.
After the Race we found the reason we were a little slow on stage. The rear differential was very stiff, we could not push the car in neutral on the concrete shop floor. We removed it after the race and it looks like it was rebuilt at some point and the output bearing was over tightened.
We are switching back to the original rear differential after replacing a leaky seal.

Enjoy the pictures and the video.



















Stiff Rear Differential Getting Changed Out. I hope this gets our speed back and faster stage times.





New Purchase to save some weight on the front end and to stop the small leak from the original 1985 radiator.






[video=youtube;MDLBO8Hr5gc]http://www.youtube.com/watch?v=MDLBO8Hr5gc[/video]

[video=youtube;VXzEWIOAVtg]http://www.youtube.com/watch?v=VXzEWIOAVtg[/video]

[video=youtube;OZR1Uj8YQ_A]http://www.youtube.com/watch?v=OZR1Uj8YQ_A[/video]
 

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Discussion Starter #87
Rear Diff work continues. Finally removed the drain and fill plug from differential from the first race car. Had to get creative on the fill plug removal.





Also replaced the leaking front seal.











Now it is time to refill and install it in the car.
Looks like we will miss Ohio this year the work schedule is not going to lineup for my brother so maybe we will spectate.
Next up Show-Me after a summer of testing and upgrades.
 

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Question: in the future will you reinforce these hubs with some plating on the side, or do you think it is not necessary?

Audi Rally Car 2.0 Update:
First here are some pictures of the drivers front suspension. This is the result of the rock that started the roll.

 

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Discussion Starter #89 (Edited)
Question: in the future will you reinforce these hubs with some plating on the side, or do you think it is not necessary?

Audi Rally Car 2.0 Update:
First here are some pictures of the drivers front suspension. This is the result of the rock that started the roll.

I do not think reinforcement is needed. We hit the rock hard enough to rip the rim apart, so at that point if the hub did not bend something else would break.



We hope to not have a hit like that again. If we do I hope it is not on a caution drops on the outside like this was.
 

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Discussion Starter #91
no kidding, glad you are OK, thank GOD for your cage. Your car is infectious, I want one now!
Yes, He was looking out for us and the cage did what is was built to do.

If you want to get into rally, just pick a car and start building or take a look at the classified ads, lots of good cars for good prices.
 

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Discussion Starter #92
In the Spirit of Southern Ohio Forest Rally (SOFR), even though we are not racing it this year. I thought I would post some rally work that has happened on the Audi.
Rear Subframe is installed with our original differential and the new radiator is installed.
We saved 11lbs by going with the aluminum radiator. The original radiator weighted 18lbs, the aluminum one is 7lbs.
The fit was good. Has all the stock mounting points. The lower mount used a smaller rubber isolator but worked fine. The thread for the temperature switch was correct. The only fitting that was a little big was the overflow fitting. Had to use a larger hose but it worked fine. The block off plug on the front is a 25mm Samco Cap.
The radiator was from ebay, worley2013, 2 core aluminum radiator for Audi 80, 90 Quattro 42mm core.

Out with the Old





In With the New





 

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The block off plug on the front is a 25mm Samco Cap.
The radiator was from ebay, worley2013, 2 core aluminum radiator for Audi 80, 90 Quattro 42mm core.
I just picked up a logbooked 2wd golf in CA, shipping it to TN soon. Thanks for the inspiration.!

Will you keep a spare samco cap or will you have someone TIG the opening shut?

Nice job saving 11lbs on the front of a nose heavy car.
 

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Discussion Starter #94
I just picked up a logbooked 2wd golf in CA, shipping it to TN soon. Thanks for the inspiration.!

Will you keep a spare samco cap or will you have someone TIG the opening shut?

Nice job saving 11lbs on the front of a nose heavy car.
I am glad we can be an inspiration. Hope to see you on stage some time. If we did not rally an Audi it would be a VW. Audi and VW are the only two types of keys on my key ring.

We probably should get it welded shut, we have a spool gun for our welder just need some practice. We will keep a homemade plug as a backup for now. I can not believe that the factory radiator is so heavy.
 

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I am glad we can be an inspiration. Hope to see you on stage some time. If we did not rally an Audi it would be a VW. Audi and VW are the only two types of keys on my key ring.

We probably should get it welded shut, we have a spool gun for our welder just need some practice. We will keep a homemade plug as a backup for now. I can not believe that the factory radiator is so heavy.
factory radiator is so heavy because of brass density, and a calculation the factory made on how much heat they needed to transfer to the coolant/air. Aluminum is cool because per unit weight, it can transfer more heat than brass, but less per unit volume. So your 18 lbs brass radiator could transfer 10 generic units of heat, but your aluminum radiator that weighs 7lbs can only transfer 9 generic units, assuming the exact same design between both radiator materials.

EDIT: changed some verbiage
 

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Discussion Starter #96 (Edited)
Show-Me Rally is almost here. Just a little prep on the car. New tires are mounted up and the Truck and Trailer are hooked up and ready to go. 33 Cars signed up so far, should be fun.







 

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Discussion Starter #97 (Edited)
Show-Me 2018 Update

2018 Show-Me Rally Update:

My brother, The normal driver of the car, could not make the rally so I made my Rally DRIVING debut with my wife as my Co-Driver in her first ever rally.
I had done some rallycross races and been co-driving for 5 seasons but it was still a different experience.
The rookie meeting and tech went well and we were ready to go. Starting towards the last, but that is expected in your first race. I did get to pick my start position and put myself behind the #140 BMW 318i. Just so I could watch and hear them launch.
Stage 1 was the super special at the Lions Club park. This was like a rallycross and it went well. Stage 2, the first real stage was the stage that my brother and I had rolled the car on at the 2015 Show-Me rally. My wife did a great job of calling that corner and we had a good time on the stage. I can not believe how stable the car is on stage, I was going rather slow but I could fell how stable controlled the car is. I am going to have to get my brother faster if that is how the car feels, we have so much more speed in the car.

The first 6 stages went well we dropped time on every rerun of stages. Stage 5 and 6 were very fast and fun.
A thunderstorm and heavy rain moved in just as we started stage 7 and we could hardly see on stage. Then as it started to let up a tree branch fell and knocked off the drivers side windshield wiper, I had to stop on stage and take the passengers wiper off and put it on the drives side, you can see us in the in-car from this youtube video at 9:35, This give you an idea of the conditions.

[video=youtube;eXBeWdD-2fM]http://www.youtube.com/watch?v=eXBeWdD-2fM[/video]

https://youtu.be/eXBeWdD-2fM

That cost a lot of time and then stage 8 was canceled due to the rain and weather causing problems with start and finish control. On the transit of the stage the drivers side wiper arm fell off, there is a picture below of the nub that was left. Switched the wiper blade back to the passengers side and we did finish with me transiting the stage and the 40min drive back to the finish looking out the passengers side of the front window. Crazy.

Enjoy the pictures and the videos below. We may have a second car build in the future and have a 2 Audi team.

Don't know what the next race will be, Our events have been taken over by the American Rally Association and we do not know what to think about that. We had no problem with Rally America and do not like the idea of paying for two rally licenses. We will see.















 

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Discussion Starter #98
[video=youtube;pk9RORAI9Mo]http://www.youtube.com/watch?v=pk9RORAI9Mo[/video]
 

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Discussion Starter #99
[video=youtube;Dh7id7Vu8E0]http://www.youtube.com/watch?v=Dh7id7Vu8E0[/video]
 

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Discussion Starter #100
[video=youtube;nBbU4WB3tTQ]http://www.youtube.com/watch?v=nBbU4WB3tTQ[/video]
 
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