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I finally have the cars set up dialled as I wanted. It's low, just right for me, it doesn't rub, it's firm but not too firm (Bilstein standard settings for now), there is some camber, no rubbing in the arch anywhere.

I'll put some pics up this weekend when I take it out for a drive.

One problem though. Although the suspensions is all new, set up symetrically, there is significant variation in the position of the face of the rim/tyre in relation to the arch:

FR 23mm
FL 11mm
RR 11mm
RL 20mm

I'm pretty sure the FR & RL have been dinged and repaired somewhere in the cars history. I'd like to bring down the variation if possible.

Although none are rubbing the FL is close, while the FR is way off. The RR sits perfectly in the arch, while the RL doens't. The RL is not really visible as a different though.

I'm trying to work out what options I have:

1) Live with it
2) Have the arches reshaped and resprayed (too much cash)
3) Is there much adjustment of subframes in our cars? My normal garage thought they would check subframe alignment when the weighting/alignment was done, but it was a quick job and no time spent to figure it out.
4) Run spacers on the wheels that need pushing out. I read about this being done on some 964s as they asymetrical arches sometimes. Doesn't sound great. If I won't notice anything, its the easiest solution. Considering this.

I'll add some pictures over the weekend.

How are everyone elses arches?

That’s weird. Mine are set up with 1 inch approx all round.
Which was done when I had the new suspension installed at unit 20.
A bit high for some but I like it.

That's really weird.

Yes, there is an adjusment on the subframe. There are a series of holes about 20mm diameter that need to line up. If they don't then your subframe has been put on wrong.

just to be clear, these are horizontal distances, not height. I have 9.5" ET40 rims so that explains the closeness of the rims to the arch.
i'll put some pictures up and the difference is clearly visible.

does this apply to front and rear subframes?
does anyone know of a resource i can look at to understand where I am looking for the subframe alignment?
anyone know how much movement there is left to right? I'd need 4.5mm but that sounds like a lot.

after a bit of digging I came across this:
https://www.audizine.com/forum/showthre ... -Alignment

is this the kind of job I'm looking at?

Good find. Pretty much your exact issue. You can see the large holes I referred to by the left yellow arrow.

I'll have a proper look and see where I get to.
The link is for a B7 A4 but I assume the principle is the same.
They talk about a 5mm adjustment. That would fix all my probelms.

Paranoia now kicking in. I will have to go and measure mine now. Thank you Alex !

I'm not going to look.

Neither am I!

Same

Must admit I had to LOOK
Although I didn’t actually measure them.
They do appear to be pretty central In the wheel arch.
PHEW I was dreading another job to add to the list.

Mine are in the arch, im happy

Here is the current set up.
You can just about see this difference:

FR 23mm
FL 11mm
RR 11mm
RL 20mm