Craig's Sport quattro build

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highlander69
Posts: 279
Joined: Thu Feb 28, 2013 7:43 am

Craig's Sport quattro build

Post by highlander69 »

I've always wanted a sport quattro, but like most people I could never affort to buy one.

Then one night over drinking some beer, 2 of my good friends Martin Pajak and Mike Hopton decided that they were going to build a couple of Sport quattro replica's. At first my knee jerk reaction was that no way I was going to undertake such a task of my own. I had just finished a complete restoration from the ground up on my 84 urq,and was in no mood to go through that again.

Long story short , Martin and Mike aquired a full sport body kit from Poland. The panels looked great. Still being the stubborn Scot that I am, I was positive that I wasn't going down this path....... :nuts:

As time went on I started thinking about it. I still had my trusty 4000 quattro with turbo conversion just sitting there doing nothing, staring at me everyday feeling neglected. I'd driven the 4000 for nearly 10 years and had many,many great memories in that car. Unfortunately the Canadian winter has taken it toll on the car.

One day I grabbed the angle grinder and cut the trunk off. I still don't really remember that part, it's as if something or someone was driving the bus that day and it wasn't me!! :wtf:
So there I was grinder in hand, looking at this poor mutilated car. My trusty old 4000 was dead, or was it :idunno: It kind of reminded me of a murderer staring at the knife after killing the victim in disbelief........

That's how my quest started in a attempt to build my own version of a Sport quattro.

The car is not going to be a true replica, but my vision of things that I would like to see on the car.

Build spec is as follows:

I want the car to look like a Road car from the outside.
The car will have a roll cage for safety reasons.
The body shell will get all the attention. I like metalwork and learning new things. I want the
underside to be as perfect as the topside.
Interior is most likely going to be something like Porsche GT3 spec.
Engine most likely 2.2 AAN, but that could change.
Transmisson O1e.
Suspension most likely custom, aluminum struts etc.
Brakes........ big.
Colour......most likely white, but that could change.
Engine bay.......carbon fibre everywhere :D

So there you have it.

I'll start adding pictures and give as much detail as possible for anyone else thinking of taking
on such a build.

Cheers,

Craig Cook.

Tartan Motorsport :flag:
highlander69
Posts: 279
Joined: Thu Feb 28, 2013 7:43 am

Re: Craig's Sport quattro build

Post by highlander69 »

The day I got my first quattro. IMO there's something special about type 85's
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highlander69
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Re: Craig's Sport quattro build

Post by highlander69 »

5 bolt converstion being done on the old girl.
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highlander69
Posts: 279
Joined: Thu Feb 28, 2013 7:43 am

Re: Craig's Sport quattro build

Post by highlander69 »

Time for more power. Turbo Transplant.

MC with a chipped computer and 3" exhaust .

It really transformed the car. Other than the gearing being too short, this car was a blast
to drive.
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highlander69
Posts: 279
Joined: Thu Feb 28, 2013 7:43 am

Re: Craig's Sport quattro build

Post by highlander69 »

The sport build begins.

Trunk cut off. Here I'm gettng my game plan together.

Why use a 4000 quattro 4 door as a build foundation for a coupe 2 door build ?

A few reasons:

I don't have a urq to cut up, and would feel bad cutting one up in the first place.
North America didn't get type 85 coupe quatto's.

By using the 4000 as a donor I already have the correct windshield angle that the sport quattro uses.
This way I won't have any weld joins at the bottom of the windshield pillar. If I had have been using
a coupe body I would have had to cut the whole roof off.

I decided to use the complete 4000 quattro floor pan minus the 320mm of course.
Going this route presents a few problems. For one it has 4 doors. Also I need to source a coupe rear end.
IMO the best way to build a sport quattro is to use a 4000 quattro front mated to a urq rear end.
Like I said I didn't have a urq to cut up, so a coupe gt rear body sheet metal would have to be sourced.

The next piece of the puzzle would be sourcing a 2 door 4000, Not a easy task in North America.
This would turn out to be alot harder than I first thought.

So basically I needed parts from 3 cars to make 1 sport quattro. :bangshead: :nuts:
Attachments
She looks so lonely sitting there!!
She looks so lonely sitting there!!
Craig 001.jpg (892.49 KiB) Viewed 46450 times
Craig 003.jpg
Craig 003.jpg (1.2 MiB) Viewed 46450 times
quattro87
Posts: 1000
Joined: Wed Feb 27, 2013 2:06 pm

Re: Craig's Sport quattro build

Post by quattro87 »

Allright Craig, Keep telling the story. 8-) I look forward to seeing how this plan came together and get up to date on the project. I figure anytime someone has to hack up three different vehicles to make one, that the project has to be considered HARDCORE. I like it.
highlander69
Posts: 279
Joined: Thu Feb 28, 2013 7:43 am

Re: Craig's Sport quattro build

Post by highlander69 »

Now we have a 2 door :D
Attachments
roof cut.jpg
roof cut.jpg (1.14 MiB) Viewed 46445 times
roof cut 2.jpg
roof cut 2.jpg (1.07 MiB) Viewed 46445 times
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chaloux
Posts: 3167
Joined: Wed Feb 27, 2013 11:43 am
Location: Muskoka, Ontario, Canada

Re: Craig's Sport quattro build

Post by chaloux »

I don't think I realized how insane you actually are...
Matt

18 Silverado 1500 work pig, roof rack and tonneau cover
11 Jetta sedan TDI DSG, rear muffler delete
GONE :( 87 4ktq - 4 FOX SNAKES

Image
Hank
Posts: 1718
Joined: Tue Feb 26, 2013 1:16 am

Re: Craig's Sport quattro build

Post by Hank »

Heck yeah Craig! Love this thing. We are only missing MIkes now. He seems pretty attached to MG!

Hank
highlander69
Posts: 279
Joined: Thu Feb 28, 2013 7:43 am

Re: Craig's Sport quattro build

Post by highlander69 »

Hank wrote:Heck yeah Craig! Love this thing. We are only missing MIkes now. He seems pretty attached to MG!

Hank


Hank, MIke should be on here very shortly. We just spoke about it over lunch and a beer.

We just got back from the sheet metal guy that's building Mikes car.

It's simply stunning.

Hopefully Mike will post some pics on here this weekend.

Cheers, :beer:

Craig.
highlander69
Posts: 279
Joined: Thu Feb 28, 2013 7:43 am

Re: Craig's Sport quattro build

Post by highlander69 »

In these pictures I'm still stripping away the sheet metal that's not needed.

The plan here is to get the car ready for adding the rear coupe gt back end.

I built a frame to keep the car braced and square. This is a very important step to
complete. The frame is also what I used to mark all my reference points for shortening and make sure
nothing have moved out of alignment after the shortening process.

I also installed a coupe door as a reference for the location of the b pillar. It's clear to see the difference
in the windshield angles between the 4000 and the coupe with the door installed.

Enjoy the pics.

Craig Cook.
Attachments
Body work 014.jpg
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Body work 004.jpg
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Body work 003.jpg
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Body work 002.jpg
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Last edited by highlander69 on Tue Mar 12, 2013 9:33 am, edited 1 time in total.
highlander69
Posts: 279
Joined: Thu Feb 28, 2013 7:43 am

Re: Craig's Sport quattro build

Post by highlander69 »

Now that I've done all I can do to the 4000, it was time to hunt down a coupe gt back end.

Time to turn this 4 door into a coupe :D

For once luck was on my side. One of my good friends John (1wheelpeel) who is in the process of restoring
his own urq was breaking a coupe gt.

So one Saturday morning I went up to his house to liberate said parts.

Cheers,

Craig Cook.
Attachments
John in action with his plasma cutter
John in action with his plasma cutter
IMG_0902.JPG (1.25 MiB) Viewed 46377 times
Finally I have the second part of the puzzle.<br />I couldn't be happier
Finally I have the second part of the puzzle.
I couldn't be happier
IMG_0907.JPG (1.4 MiB) Viewed 46377 times
highlander69
Posts: 279
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Re: Craig's Sport quattro build

Post by highlander69 »

Next step is to get this coupe back end on to the 4000 floor pan so as I can get my game plan together.

First of I had to prep the coupe sheet metal in order the have a trial fit on the car.

Once I had the coupe back end sitting on I could figure out the b pillar location.

Martin took a video of the two pieces being offered up for the first time

http://youtu.be/b29B-yvFUfE

Cheers,

Craig Cook.
Attachments
If the factory can do it, I can do it!!
If the factory can do it, I can do it!!
Sport evolution.JPG (102.87 KiB) Viewed 46362 times
IMG_0922.JPG
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coupe back end 2.JPG
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back end on car 2.JPG
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Coupe back end sitting on the 4k floor pan for the first time. Not pretty but sitting on . We now have a coupe!!
Coupe back end sitting on the 4k floor pan for the first time. Not pretty but sitting on . We now have a coupe!!
back end on car.JPG (39.28 KiB) Viewed 46377 times
Last edited by highlander69 on Tue Mar 12, 2013 11:14 am, edited 1 time in total.
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chaloux
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Location: Muskoka, Ontario, Canada

Re: Craig's Sport quattro build

Post by chaloux »

:hail:
Matt

18 Silverado 1500 work pig, roof rack and tonneau cover
11 Jetta sedan TDI DSG, rear muffler delete
GONE :( 87 4ktq - 4 FOX SNAKES

Image
highlander69
Posts: 279
Joined: Thu Feb 28, 2013 7:43 am

Re: Craig's Sport quattro build

Post by highlander69 »

Now that the car had been converted to a coupe it was time to start the shortening process.

I carefully markout out on my jig the dimensions to be cut and then cut out a piece of the floor.

Cheers,

Craig Cook.
Attachments
Now basically slide the car together and we have a shorty !!
Now basically slide the car together and we have a shorty !!
Body work 008.jpg (1.01 MiB) Viewed 46373 times
Body work 009.jpg
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Body work 010.jpg
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Floor be gone
Floor be gone
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Hank
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Re: Craig's Sport quattro build

Post by Hank »

Who is going to finish first Craig?
highlander69
Posts: 279
Joined: Thu Feb 28, 2013 7:43 am

Re: Craig's Sport quattro build

Post by highlander69 »

Now the fun car really begin. The day has arrived to shorten the car.

In these pictures the car has been shortened,but still has about 20mm to go.

Martin came over to help out with the fun part.

Again we took a few videos of the process. A little elbow grease and the car came together !!

http://youtu.be/w7XwL7B1HbM

http://youtu.be/dsm2iS200KM


We have a shorty............. :D

Cheers,

Craig Cook.
Attachments
urq sport comparison 001.jpg
urq sport comparison 001.jpg (1.18 MiB) Viewed 46368 times
Getting there
Getting there
Shortening the car 009.jpg (1.17 MiB) Viewed 46368 times
Shortening the car 001.jpg
Shortening the car 001.jpg (941.03 KiB) Viewed 46368 times
highlander69
Posts: 279
Joined: Thu Feb 28, 2013 7:43 am

Re: Craig's Sport quattro build

Post by highlander69 »

Hank wrote:Who is going to finish first Craig?



That's a tough question Hank.

Mike is pretty much in the lead now from a body work standpoint.

Martin is way ahead with part acquisition , but behind in body work.

I'm kind of in the middle with a broken ankle at the moment :bangshead: but stuggling on.

The neat thing about these builds is that although they will all look like sport quattro's from the outside,
the build details are going to be miles apart.

So I'm not really sure who will finish first.

Cheers,

Craig
highlander69
Posts: 279
Joined: Thu Feb 28, 2013 7:43 am

Re: Craig's Sport quattro build

Post by highlander69 »

Now on to the hard part.

Where the hell am I going get a 2 door in North America :bangshead: :bangshead:

I guess the Audi god's must have been approving my build. One of the audi group members
had a 2 door he was willing to break for me :ty: :hail: :hail:

I NOW HAVE ALL THE PARTS FROM 3 CARS TO BUILD MY OWN SPORT QUATTRO :drive:

Jim (glibobbo21) had just what I needed. Although it was over a 20 hour round trip, I couldn't get there fast enough.

So after driving for over 10 hours we arrived at Jim's place.

Here's Jim looking quite scary cutting the car up!!
Attachments
Jim the madman cutting the car up!!
Jim the madman cutting the car up!!
Car fell off the hoist!!.JPG (1.03 MiB) Viewed 46363 times
23 hours later. I have a b pillar!!
23 hours later. I have a b pillar!!
2 door roof prepped 002.jpg (1.57 MiB) Viewed 46363 times
B pillars nearly prepped for fitting. I didn't use any of the front roof structure piece,just the side pillar portions.
B pillars nearly prepped for fitting. I didn't use any of the front roof structure piece,just the side pillar portions.
IMG_1256.JPG (642.66 KiB) Viewed 46363 times
Last edited by highlander69 on Tue Mar 12, 2013 12:48 pm, edited 1 time in total.
highlander69
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Re: Craig's Sport quattro build

Post by highlander69 »

Now that the car has been shortened, it's time to get some strengh back in to this unibody.

First, I sat the roof on to verify fit.

As hoped, it looks great 8-)


Cheers,

Craig Cook.
Attachments
Roof installation 005.jpg
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Roof installation 006.jpg
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Roof installation 004.jpg
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sport quattro 007.jpg
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highlander69
Posts: 279
Joined: Thu Feb 28, 2013 7:43 am

Re: Craig's Sport quattro build

Post by highlander69 »

Now it was time to get that b pillar welded in.

I installed the b pillar in 1 complete piece. Most people cut the b pilllar in half.
This way is a stronger way to do it.

So for the first time I have the correct b pillar and door on the car. It's starting to look like
a car again.

Cheers,

Craig Cook
Attachments
Roof installation 003.jpg
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IMG_1259.JPG
IMG_1259.JPG (637.21 KiB) Viewed 46355 times
b pillar installed 001.jpg
b pillar installed 001.jpg (909 KiB) Viewed 46355 times
highlander69
Posts: 279
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Re: Craig's Sport quattro build

Post by highlander69 »

More unibody work on the car.

My goal is to make the car stronger than even the factory sport quattro road car was. Even
before I install the roll cage. A strong platform to build from is a must.

I bent up my outer rockers in a heavier gauge metal than the factory used.

I also installed a complete mid inner rocker in a heavier gauge metal. This part alone has increased the unibody
strength significantly. :D

Cheers,

Craig Cook.
Attachments
urq inner rocker panels 004.jpg
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urq inner rocker panels 012.jpg
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urq rocker panels 002.jpg
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Last edited by highlander69 on Tue Mar 12, 2013 12:22 pm, edited 1 time in total.
highlander69
Posts: 279
Joined: Thu Feb 28, 2013 7:43 am

Re: Craig's Sport quattro build

Post by highlander69 »

A few more on the rocker detail.

By installing the mid inner rocker piece, I was able to seam weld the a and b pillars together.
This increased the strength significantly. Something the factory never did.
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urq inner rocker panels 007.jpg
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urq inner rocker panels 006.jpg
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urq inner rocker panels 005.jpg
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urq inner rocker panels 002.jpg
urq inner rocker panels 002.jpg (955.71 KiB) Viewed 46352 times
glibobbo21
Posts: 659
Joined: Wed Feb 27, 2013 11:51 am

Re: Craig's Sport quattro build

Post by glibobbo21 »

yes!
Audiurq
Posts: 43
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Re: Craig's Sport quattro build

Post by Audiurq »

These dimple dies look familiar, I hope we don't wear them out before Martin needs them ;)

Thanks for the loan :beer:
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