Mike's big RS4 modding project

[MikeFish]

So I started modding the power steering fluid cap the other day.

It started off like the photos in my earlier thread.
Then I separated the diptstick part from the actual lid and it looked like this:





Looks like it was just glued in with a few dollops of glue. It also looks like the glue on the outer circle are what is keeping the silver bit of the cap to the black bit so I was careful not to make the whole thing fall apart.

Next job was to get rid of all the prongs sticking out.

I got them this far by hand:



Next I need to get the dremmel out and grind them all right back and also remove the parts that are recessed into the handle.
Then the next bit would be to cut the top off the original cap. I didn't want to do this to the original one just in case it wasn't a success. So I ordered a new one. Once that turns up I can cut the top off and size it up with the R8 cap.

I'm not even sure the cut-out in my carbon cover in the engine bay is big enough for this lid to pass through. I just had a thought, I could check the size against the original cover as I still have it in the garage (the fluid reservoir doesn't allow me to lower it enough to check the opening in situ).

And as described in my stereo modding thread I have removed the number plate light / lock assembly for a little research. More details in my stereo modding thread.

[MikeFish]

I'm also looking into doing the seat backs and interior trims again. Looking for a cheap set of trims to experiment with.

Got a load of trims in the post now. Need to get them covered now.

[Rick_RS4]

looking good, looks like the cap will work out fine, make sure the parts are squared up when the bottom is in fully closed on the reservoir tho.

what extra trims are you getting, im thinking about doing the back of my seats in suede

[MikeFish]

Oooh brave choice. I couldn't have it with kids, it'd be ruined in no time. Actual suede or alcantara like kev? Unless you never have anybody in the back I think it's a bad idea. It looks nice but I'd be too worried about it getting ruined.

I've got a spare set of trims now so I think I will try the white limited edition 'stormtrooper' look but in a black car.

[Rick_RS4]

Oooh brave choice. I couldn't have it with kids, it'd be ruined in no time. Actual suede or alcantara like kev? Unless you never have anybody in the back I think it's a bad idea. It looks nice but I'd be too worried about it getting ruined.

I've got a spare set of trims now so I think I will try the white limited edition 'stormtrooper' look but in a black car.

yeah maybe alcantara, dont have many people in the back, that or gloss black

you mean paint the carbon part trims white? that would look pretty smart

[MikeFish]

I was thinking of getting them wrapped in gloss white. I guess painting is an option too. I figured I'd probably get a better finish with a wrap as they are quite shiney to start with and would need keying etc for the paint to take properly.
I've got all the spare trims to try it now. The only problem is that the rear ash tray cover I have is sort of dimpled as it matches the finish of the centre console and not smooth like the my carbon one. And the front ash tray cover is curved but my original carbon one is flat so I might have to find another flat (and not dimpled) one. I don't actually have the front ashtray in at the moment as that is where the controller for my processor lives but I thought I'd get it done anyway in case the controller came out at any point.

Do you know if there is any problem with starting / driving the car with the passenger seat removed? I assume I will get some warnings but will they self clear when the seat goes back in (or clear with VCDS)? I was thinking of dropping my passenger seat and trims in for wrapping then go get the driver's seat done when the rest are ready. Or just drop the whole lot in there and live without the car for a week!

[Rick_RS4]

I was thinking of getting them wrapped in gloss white. I guess painting is an option too. I figured I'd probably get a better finish with a wrap as they are quite shiney to start with and would need keying etc for the paint to take properly.
I've got all the spare trims to try it now. The only problem is that the rear ash tray cover I have is sort of dimpled as it matches the finish of the centre console and not smooth like the my carbon one. And the front ash tray cover is curved but my original carbon one is flat so I might have to find another flat (and not dimpled) one. I don't actually have the front ashtray in at the moment as that is where the controller for my processor lives but I thought I'd get it done anyway in case the controller came out at any point.

Do you know if there is any problem with starting / driving the car with the passenger seat removed? I assume I will get some warnings but will they self clear when the seat goes back in (or clear with VCDS)? I was thinking of dropping my passenger seat and trims in for wrapping then go get the driver's seat done when the rest are ready. Or just drop the whole lot in there and live without the car for a week!

yeah wrap would be a better idea, if your wrapping you could just wrap your standard carbon ash tray?

if you take out the passenger sea it will be fine, i dnt think there will be a fault on the airbag as it doesnt have one, only the comfort seats do, so will reset fine.

[Covkiller]

Any reason why you haven't changed your coolant reservoir
I changed mine as it went beige too, I think it cost £16
No offence meant, great thread on some fantastic mods

[MikeFish]

I was thinking of getting them wrapped in gloss white. I guess painting is an option too. I figured I'd probably get a better finish with a wrap as they are quite shiney to start with and would need keying etc for the paint to take properly.
I've got all the spare trims to try it now. The only problem is that the rear ash tray cover I have is sort of dimpled as it matches the finish of the centre console and not smooth like the my carbon one. And the front ash tray cover is curved but my original carbon one is flat so I might have to find another flat (and not dimpled) one. I don't actually have the front ashtray in at the moment as that is where the controller for my processor lives but I thought I'd get it done anyway in case the controller came out at any point.

Do you know if there is any problem with starting / driving the car with the passenger seat removed? I assume I will get some warnings but will they self clear when the seat goes back in (or clear with VCDS)? I was thinking of dropping my passenger seat and trims in for wrapping then go get the driver's seat done when the rest are ready. Or just drop the whole lot in there and live without the car for a week!

yeah wrap would be a better idea, if your wrapping you could just wrap your standard carbon ash tray?

if you take out the passenger sea it will be fine, i dnt think there will be a fault on the airbag as it doesnt have one, only the comfort seats do, so will reset fine.

Ok, thanks Rick, I assumed the passenger seat had airbags. Does the driver's bucket seat not have one either?

[MikeFish]

Any reason why you haven't changed your coolant reservoir
I changed mine as it went beige too, I think it cost £16
No offence meant, great thread on some fantastic mods

Yes, there's a good reason (well, sort of). I ordered a new one from ebay but when I went to install it I noticed the inlet pipe is positioned at the back left behind the cap but the one I bought had the inlet pipe at the front. Havent got round to ordering another one yet. Been looking for new carbon engine covers too but have only seen ones that are discoloured or the red sticker has started to come off.

[MikeFish]

Some of the gloss black trims waiting for a wrap:


I could wrap my carbon ash tray covers but I hoped for a complete set of wrapped and carbon but I guess if I ever go back to carbon I won't be going back to white again so can just take the wrap off.

The new power steering cap arrived so off came it's head:


Then I ground down some of the R8 cap:


Then I ground down a bit more of the B7 cap:


Then I test fitted the 2 together:


I will grind down a little more tomorrow but I can't go much lower for 2 reasons:
1) It will start to fall apart and weaken
2) I need a little height difference between the 2 otherwise the R8 cap will wedge into the small opening in the RH engine cover

Just need to get some high temperature epoxy or something similar tomorrow to bond the 2 parts together.

[PetrolDave]

Ok, thanks Rick, I assumed the passenger seat had airbags. Does the driver's bucket seat not have one either?

The bucket seats don't have side airbags, which is one of the reasons why the US market didn't get the bucket seat option. Without them the side impact rating is lower, which wouldn't go down well in the US market.

[MikeFish]

Ok, thanks Dave.
I also read somewhere something about the bolts being single use so should be renewed when refitting the seats. Is this true?

[MikeFish]

Tada!


I had deliberately set it so that when it was fully tight the logo would be horizontal. In this photo I didn't fully tighten it as it had only been set for about 3 hours. There was just enough turn left on it to make it just right.



I had to use some 2 part rapid setting Araldite in the end. I don't think it is very highly rated temperaure wise but I will keep an eye on it and see how it holds out.



I thought it best to seal around the edges just to make sure it was air tight. High temperature silicon used.

[Rick_RS4]

love it, do you have a part number? please