Audi 4.2 V8 in a 924.

[Golten951]

Julian Thompson said:

If I can offer you a little food for thought about the dash - it’s not possible to cover every object in every substrate.

You have to plan what is, and is not going to work and then react. Remember the manufacturer has a vacuum forming facility for vinyl trim and you don’t, so you’re at a disadvantage before you begin. Also, picking a tartan to go around corners means that, much like a carbon weave, you will always be fighting a losing battle aesthetically unless you learn to sew seams and actually make a cover panel that fits the shape.

Thanks for the input. I am just having fun and enjoying the challenge.

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Caddyshack said:

Big Tomm said:

I love the look of these square dash interiors but I hate them passionately at the same time! Every one I’ve ever had has been cracked to bits, all distorted around the cluster where they’ve cracked the whole way through. Doubled with the fact that trying to repair one and rewrap it is a nightmare due to its shape. I see that a few companies are selling dash caps which doesn’t fix the problem but makes it look a lot better I’m sure.

Fair play for having a go at recovering the dash. It’s certainly not an easy task to undertake. Neither is a V8 conversion for that matter.

Fill the cracks and flock it and it would be good as new, just non standard finish.

I had an oval dash before and my new one is square and I used to hate the square, no I love the old Skool effect.

that is the best way to go if you do not want to strip and attempt to recover the whole thing. Agreed caddy, the Square is a nice set up.

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Placement for my Steering column. the distance is good and I have sorted the placement to be able to use the power adjust, which is pretty cool!

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Things have been crazy lately, hence the lack of anything done. I did get to get some small stuff done. But sometimes that is all you can do. I cleaned up and Painted the 944 Turbo Calipers I am installing on my 924.

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gforceg said:

I'd been wondering how this was going recently. Good work on those calipers.

Thank you. My 3rd kiddo was recently born and will be moving house soon lol. I will update more when possible.

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InitialDave said:

Nice job on the calipers. Do they work with the original master cylinder, or does it need the matching 944 one?

hey man, Thank you! I will have full manual brakes with a reverse cylinder set up. I will add pictures of the set up I am using. Fronts get a 1"/25mm master, rears get a 7/8"/22,, master and the clutch gets a 3/4"/19mm master. Really nice set up and makes it do the braking system does not interfere with the Head. Here is a link of the part to give you an idea. https://www.wilwood.com/Pedals/PedalProd?itemno=34...

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Here are 2 pictures of the rough placement for my brake/clutch masters.

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Did some work on my 4.2L intake. The lower air gate was jammed to the shut position which ends up breaking the Actuator arm. Next I will be sealing the intake back up and the wrapping it up for transport back up to my Dad's place where my 924 is.






Here is a picture showing the actuation of these gates.

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carinaman said:

Congratulations on the new baby. The calipers look great. I wasn't aware of the torque extending flap on the V8.

Thank you very much on both, He is doing great and growing well. Was pretty cool to learn about for sure, Normally if one of this gates/flaps break they really mess with your engine make it run really sluggish. Some intakes have a roller system and others have only one on the inside .

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Come the end of this Month I will be able to work on my 4.2L swap a lot more. Since my 924 will be in my possession and not sitting at my Dads house. Very excited to get working on her again. ! I will up date when I start. Have a HUGE list to do lol.

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Worked on my Audi V8 headers for my 924 I still need two 3 to 2.5 reducers. they are just primed right now to keep some of the elements off the metal. They turned out pretty nice for mocking up on the car and then finishing off in my driveway. I used a header kit from Summit, then sliced the flanges off the stock A8 manifolds. They are not prefect. But will certainly do the job I need them to do.

[Golten951]

SturdyHSV said:

Really enjoy proper build threads, keep up the great work!

Thank you very much. I appreciate that ^_^

carinaman said:

They look OK to me.

Thank you. they are no perfect or super pretty, but will work for me. Working under the car in a driveway then having basic tools to build them. Turn out well.

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I was able to do a little bit of work on my 924. I have the steering wheel and column set where I want. It will be electronically controlled for adjustment. Also gave my 924 a bit of a clean up after 5 years. Removed the 4 fog lights I had mounted to the bumper as well. going with a different idea for them. I will be Welding in brackets tomorrow to hard mount the steering column in place then I can work on the Brake and Clutch pedal.

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Hey all. Got some more good progress done on my swap 924 V8.
Pedal box is all set up and welded.
Steering column is in and all welded.
Put the Instrument cluster in place just for fun to see how it looks.
Put the intake manifold in place and spaced up since I needed to flip is 180 degrees from the normal set up. I rotated the throttle body as well to clear the hood. I need to have a 10mm space made for the throttle body to intake. really happy with it all

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hyphen said:

Very good work enjoying reading about your build.

Will you be using an aftermarket steering wheel? As that Audi branded one just looks so wrong!

Edited by hyphen on Sunday 1st November 08:41

Thank you hypen! Been a lot of fun doing this.
I am keeping the Audi wheel. but It will be made blank with nothing on it.

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More good progress today on my 924 Audi V8.
Finished getting my brake pedal box tacked in place. Need to make a lid for it next. Put the coolant reservoir in plan where I want to set it up.battery is going into the drivers side cubby hole.
Test fitted my A8 instrument cluster into the 924 dash. Fit great after I cut material away lol. Reason for using all the A8 stuff like whole steering column, steering wheel and cluster is I have to complete interior, exterior and engine harness from the A8 I got the engine from. Will make the wiring a lot smoother on install VS trying to match up all the 80s wiring to the newer 2000s wiring. A8 steering wheel will either be blank or might make my own special emblem for it.

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More good progress on 924 4.2L. Engine harness laid out and made a neat little metal lid for it so it can be removed.
Lid for my Pedal box and a few other good things. ALso have all 3 pedals set up.

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The Rotrex Kid said:

Great work!

Thank you ^_^

Bullet-Proof_Biscuit said:

*Starts shopping for 924s & Audi V8s.....

Lol it is a monster undertaking. But super super fun!!

[Golten951]

Paul S4 said:

Amazing build and seems a lot of work.

Each to their own ..... but I agree with a previous poster about the dash: I would sand it down, fill all the cracks etc and then send it away to get 'flocked' in black/brown to match the interior. The tartan makes it look a bit like a 1970s Lotus Esprit interior,,,,! ( And I used to have a 1970 Elan which thankfully had black vinyl/wood dash. !)

I used to do a lot of work on my Elan, but all standard maintenance etc, I cannot imagine how much time it takes to do all that engineering/fabrication work.

Very interesting project.

Thank you Paul! It has been a lot of work. but 100% worth it. This is going to be a bonkers and fun car.

I put the dash work completely on hold for now. But I am going to go with Blue vinyl. Brown and black are just a bit boring and does not match my brain or attitude lol!

The Elan is a pretty car. I have always liked Lotus cars. For time. I am close to 200 hours in fabrication and design.

I do appreciate that insights and knowledge. Keep on a chugging away and wrenching ^_^

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Bullet-Proof_Biscuit said:

I'd be interested to see them if you have any photos of the engine to clutch housing / torque tube connection? I admit when I saw this thread I half hoped you'd found a way of using factory bolt together parts, as that Audi V8 bolts up to a fair few Porsche transmissions, albeit 20 year newer ones!!!

When I pull the engine out to mount the Flywheel I will get pictures. But I am using the 924 Turbo bell housing and had a V6 spacer welded to it. that gives me the mounting holes I need. Then the 924 turbo bell housing attaches to the torque tube in the stock manner. I was considering a new Cayman gearbox. But they are really expensive.