Depression beater…
Discussion
B'stard Child said:
You weren't the only one - a company that has ruined the internet in terms of build threads across the world
I had a paid for account with them when they pulled that famous stunt - had no regrets in deleting everything except a "f
k you Photobucket image"
likewise... i had paid for years, i found in recent times that the storage amount got less but the price (or plans) kept changing... got sick of it.I had a paid for account with them when they pulled that famous stunt - had no regrets in deleting everything except a "f
k you Photobucket image" So far imgbb seems to be ok (time will tell obvs)
today being a little warmer and dry an easy job to remove the radiator cover and bring into the warm, my excuse being that the adhesive sticks better when warm, rather than me freeze my backside off outside...
A thorough clean, degrease and dry and then a wipe over with acetone (secretly nail varnish remover, which i saw some brands are now coming acetone free...!!!)
state of the old decal...
definitely not stuck and all wrinkly... making sure the placement was correct (i was sad and measured it lol) and the new one applied
then just a simple case of refit as removed...
not as exciting as engine rebuilding or chassis dynamics yet but it makes me feel good about it and now i know i don't have a manky flappy decal every time i left the bonnet lol
A thorough clean, degrease and dry and then a wipe over with acetone (secretly nail varnish remover, which i saw some brands are now coming acetone free...!!!)
state of the old decal...
definitely not stuck and all wrinkly... making sure the placement was correct (i was sad and measured it lol) and the new one applied
then just a simple case of refit as removed...
not as exciting as engine rebuilding or chassis dynamics yet but it makes me feel good about it and now i know i don't have a manky flappy decal every time i left the bonnet lol
The S5 has been doing what any S5 does, normal service and killing the environment 1tank of fuel at a time... until last week when on exiting a dual carriage roundabout and accelerating back to the NSL she held back and a Check light came on and was in limp mode....
Got home and plugged the laptop in and was greeted by a "P0087"code.... bugger fuel pumps...
being an engineer and a tight wad meant there is feck all way i was just going to go out and buy 2 new HPFP's (even though that is the easy option). I wanted to understand what the exact failure was...
Was it mechanical, or was it electrical???
Eliminating the actuator drive from the camshaft, as these can wear i removed both pumps.
and the cam driven actuator
i won't bore you with pics of both pairs lol
no wear on the actuator, nor the camshaft lobe on either side.
The fuel pumps themselves are easy to dismantle and will show any signs of internal wear, i am waiting on some brake cleaner as i had ran out, but i am not expecting any mechanical issues, what i suspect is it's sensor failure.
these ones specifically, of course you cannot buy them from Audi as you have to buy the whole fuel pump... they must be available somewhere (either OE or as a pattern replacement), took a bit of digging and scouring the net but found a supplier of them and have ordered a pair to see what effect putting new sensors have... delivered price is less than £70 which is a damn sight cheaper than the £700 each HPFP is....
On the left hand fuel pump there is also another sensor and it looks like it's had a previous interaction from someone as it has been "expertly" epoxied
to be fair they didn't do to be a job repairing the plug socket but this sensor will be replaced, again to eliminate it....
the next cheapest part to replace is the low pressure pump which sits in the tank, as i suspect that will be the original 120,000 mile old item...
watch this space.....
Got home and plugged the laptop in and was greeted by a "P0087"code.... bugger fuel pumps...
being an engineer and a tight wad meant there is feck all way i was just going to go out and buy 2 new HPFP's (even though that is the easy option). I wanted to understand what the exact failure was...
Was it mechanical, or was it electrical???
Eliminating the actuator drive from the camshaft, as these can wear i removed both pumps.
and the cam driven actuator
i won't bore you with pics of both pairs lol
no wear on the actuator, nor the camshaft lobe on either side.
The fuel pumps themselves are easy to dismantle and will show any signs of internal wear, i am waiting on some brake cleaner as i had ran out, but i am not expecting any mechanical issues, what i suspect is it's sensor failure.
these ones specifically, of course you cannot buy them from Audi as you have to buy the whole fuel pump... they must be available somewhere (either OE or as a pattern replacement), took a bit of digging and scouring the net but found a supplier of them and have ordered a pair to see what effect putting new sensors have... delivered price is less than £70 which is a damn sight cheaper than the £700 each HPFP is....
On the left hand fuel pump there is also another sensor and it looks like it's had a previous interaction from someone as it has been "expertly" epoxied
to be fair they didn't do to be a job repairing the plug socket but this sensor will be replaced, again to eliminate it....
the next cheapest part to replace is the low pressure pump which sits in the tank, as i suspect that will be the original 120,000 mile old item...
watch this space.....
so, continuing on with the fuel pumps....
finally a package arrived
all looked good inside, had the correct Hitachi part numbers on them...
hmm, tool needed to remove and refit... i don't have a 36mm open ended spanner so a hunt around for an old socket which could be modified...
a little bit of a tickle with Mr Anglegrinder and job jobbed....
the old crusty ones came off easily
and refitting was a simple screw on affair...
the plug part just needed aligning with the electrical plug, which was a simple case of rotating it to align then finish tightening the sensor down...
start up was much improved, wasn't sluggish like before and fired instantly, all pressures look good as shown on VCDS and now no codes.....
job ticked off and a massive saving over needing to replace the HPFP's...!!!
finally a package arrived
all looked good inside, had the correct Hitachi part numbers on them...
hmm, tool needed to remove and refit... i don't have a 36mm open ended spanner so a hunt around for an old socket which could be modified...
a little bit of a tickle with Mr Anglegrinder and job jobbed....
the old crusty ones came off easily
and refitting was a simple screw on affair...
the plug part just needed aligning with the electrical plug, which was a simple case of rotating it to align then finish tightening the sensor down...
start up was much improved, wasn't sluggish like before and fired instantly, all pressures look good as shown on VCDS and now no codes.....
job ticked off and a massive saving over needing to replace the HPFP's...!!!
In my mind all the little jobs make the overall picture bigger and improvements are my satisfy for the mental state….
As my S5 is missing the main engine cover, as a side note I don’t want the cover as it would go in the bin if I ever supercharged the thing, however in the meantime the inlet manifold isn’t as clean as it should be….
So with 30 minutes spare…. This was its current state….
normal degreasers weren’t touching the imbedded crud. So from back in my architectural steelwork days I developed various patination methods for the company’s I was employed in and I have a variety of nasty chemicals… I have an awful smelling stainless steel deoxidiser….
that worked lol
simple case of spray on, agitate and rinse with copious amounts of water and then dry off so as not to stain the plastics….
As my S5 is missing the main engine cover, as a side note I don’t want the cover as it would go in the bin if I ever supercharged the thing, however in the meantime the inlet manifold isn’t as clean as it should be….
So with 30 minutes spare…. This was its current state….
normal degreasers weren’t touching the imbedded crud. So from back in my architectural steelwork days I developed various patination methods for the company’s I was employed in and I have a variety of nasty chemicals… I have an awful smelling stainless steel deoxidiser….
that worked lol
simple case of spray on, agitate and rinse with copious amounts of water and then dry off so as not to stain the plastics….
We’ve all been there…. that little nag in the back of our minds as to the curiosity as to the condition of something, knowing full well that a mahoosive can of worms is about to unfold…. on the other side of that curiosity is a little voice telling us to not look, too not attempt and leave it for another day…. do we listen? nope….!!!
So a bit of a backstory as to how we got to here, my okd S5 had slight corrosion in a couple of places, all dealt with and sorted, so there I was looking through old pics of S5 number 1 and I saw the work I did on the boot surround.
Hmmmmm I’ve not looked under the seal of S5 number 2…… I know I’ll go and have a little look, what harm could it do? I mean, it’s a sunny day, the birds are singing and all’s well in the world, right?
Feck, feck, feckerty feck…..!!!
quite deep in the whole seam…… all around the whole aperture…..
on first poke it’s all solid but needs dealing with ASAP
Off to place an order for some BiltHamber Deox Gel and some paint….!!!
So a bit of a backstory as to how we got to here, my okd S5 had slight corrosion in a couple of places, all dealt with and sorted, so there I was looking through old pics of S5 number 1 and I saw the work I did on the boot surround.
Hmmmmm I’ve not looked under the seal of S5 number 2…… I know I’ll go and have a little look, what harm could it do? I mean, it’s a sunny day, the birds are singing and all’s well in the world, right?
Feck, feck, feckerty feck…..!!!
quite deep in the whole seam…… all around the whole aperture…..
on first poke it’s all solid but needs dealing with ASAP
Off to place an order for some BiltHamber Deox Gel and some paint….!!!
Edited by 89forever on Sunday 4th June 14:18
Edited by 89forever on Sunday 4th June 14:37
deebs said:
I have the same year car on 80k miles (owned for 5 years) I've never looked under the seal. I don't want to now 
. I did have rust on the inside lip of the front wings taken care of recently. I have spots of rust where the light clusters meet the boot as well that I need to get a move on and look at.
My previous S5 was an ‘07 with 72k on it and that had the same issue under the seal. . I did have rust on the inside lip of the front wings taken care of recently. I have spots of rust where the light clusters meet the boot as well that I need to get a move on and look at. Sorry to be the bearer of bad news but I’d be surprised if it’s not similar…..
word of warning when removing your seal though, in the middle at the bottom is a glued joint where the ends of the seal are made into a loop. Careful not to break the glue joint.
well as today is Father's Day what better time to spend some quality me time.... the fam has been shipped off to do grandparent stuff so a lovely quiet day for me to get on with the rust issues.....
So, the patient was partially stripped of lights and inner boot linings etc....
so i could get a proper look at what was needed to be addressed. As i have said previous none of the seams had been blown apart by the rust so thankfully all surface issues which makes this a far easier task.
But it still wasn't pretty
it was pretty much like this around the whole seam of the boot opening and the rear bumper needed removing to get on the underside...
bumper off and the crash bar isn't pretty at all....
yuk...!!! that's going off to be shot blast and powdercoated as whilst i'm in there it would be daft not to....
all of the corrosion has been ground away to fresh steel with a wire brush attachment on an angle grinder
shiny steel at last....
all painted edges will be feathered before painting, then it was onto applying the Deox Gel and wrapping in cling film....
and leave to sit for 2 hours, i then did a 2nd application and am now sat waiting another 2 hours, hence doing this part one of this write up today lol....
When i took the rear bumper off there were signs that there hath been the hand of idiot before me....
well that was clearly a decent paint job... well done feckwit... at least it means there's a huge amount of paint here, so armed with a brand new stanley blade it has been reduced to this...
needs a little bit more refining but loads better than before.....
Part 2 soon....
So, the patient was partially stripped of lights and inner boot linings etc....
so i could get a proper look at what was needed to be addressed. As i have said previous none of the seams had been blown apart by the rust so thankfully all surface issues which makes this a far easier task.
But it still wasn't pretty
it was pretty much like this around the whole seam of the boot opening and the rear bumper needed removing to get on the underside...
bumper off and the crash bar isn't pretty at all....
yuk...!!! that's going off to be shot blast and powdercoated as whilst i'm in there it would be daft not to....
all of the corrosion has been ground away to fresh steel with a wire brush attachment on an angle grinder
shiny steel at last....
all painted edges will be feathered before painting, then it was onto applying the Deox Gel and wrapping in cling film....
and leave to sit for 2 hours, i then did a 2nd application and am now sat waiting another 2 hours, hence doing this part one of this write up today lol....
When i took the rear bumper off there were signs that there hath been the hand of idiot before me....
well that was clearly a decent paint job... well done feckwit... at least it means there's a huge amount of paint here, so armed with a brand new stanley blade it has been reduced to this...
needs a little bit more refining but loads better than before.....
Part 2 soon....
Part 2 of todays fun n games
whilst the rear bumper was off, the screws which hold one of the trims on were not looking their best
there were about 8 of the buggers merrily rusting away, i was sure in my stash of many things i had an equivalent..
the head was a Philips and slightly larger but close enough, especially as it's now hidden and no one else will ever see it, well except the internet but i know you guys will never say anything....!!!
much better.....
and now it all got a bit painty sprayey and i created clouds of spray dust... a very minor breeze through the open garage stopped me gassing myself.... as i'm an amateur i totally disregarded any form of PPE.
first coat was to hit it with Electrox
lays down like your first date on Prom Night, easy and lovely...
2 coats of that, job jobbed.... then onto primer and base coat....
that needs an hour and i might actually get some lacquer on it this evening.....
getting there....
whilst the rear bumper was off, the screws which hold one of the trims on were not looking their best
there were about 8 of the buggers merrily rusting away, i was sure in my stash of many things i had an equivalent..
the head was a Philips and slightly larger but close enough, especially as it's now hidden and no one else will ever see it, well except the internet but i know you guys will never say anything....!!!
much better.....
and now it all got a bit painty sprayey and i created clouds of spray dust... a very minor breeze through the open garage stopped me gassing myself.... as i'm an amateur i totally disregarded any form of PPE.
first coat was to hit it with Electrox
lays down like your first date on Prom Night, easy and lovely...
2 coats of that, job jobbed.... then onto primer and base coat....
that needs an hour and i might actually get some lacquer on it this evening.....
getting there....
and Part 3 to round off today, as i'll be waiting on the powder coating and new mounting bolts for the crash bar...
a before and after shot, all went lovely which was good for the mental instabilities....!!!
and from underneath....
the lacquer needs to cure overnight before the seal goes back on, and before that the seal needs internally cleaning so there's no crud inside, i'll lubricate the seal at the same time to prolong it's life....
one small step...
a before and after shot, all went lovely which was good for the mental instabilities....!!!
and from underneath....
the lacquer needs to cure overnight before the seal goes back on, and before that the seal needs internally cleaning so there's no crud inside, i'll lubricate the seal at the same time to prolong it's life....
one small step...
Tom4398cc said:
That is seriously impressive work OP, hats off to you.
If you’d ever like a 211,000 mile 2004 L322 Range Rover to come for a holiday at your house, do just say!
thanks bud, appreciate it....If you’d ever like a 211,000 mile 2004 L322 Range Rover to come for a holiday at your house, do just say!
sadly i'd have to decline the kind offer of your RR coming for a stay, my area of expertise is totally within the 4 rings of Audi i'm afraid... now if you'd offered a Q7 or Cayenne i fancy doing an Overland conversion....!!!
it's safe to safe the world has officially gone mad..... (more mad?)
Having spent the last 2 weeks trying to find a local to me company which could simply bead blast and powder coat the bumper bar i failed miserably. those i contacted either didn't reply or came back with a stupid cost.
now to be fair i've probably been isolated from being a member of the public, paying retail prices as for many years i've had access to do this simple task through the companies i have worked in and either got it done free of charge or paid a small amount due to the jobs i've put through my various suppliers...
i visited one company and with a straight face they offered to undertake the task for £80.... errr no thanks, i said and walked away shaking my head in utter disbelief.
I then changed tactics and tried finding a company to just bead blast it... found one and good communications from them, how much i asked? £50 please they said, i questioned that they understood the assignment and that it was just for this single piece and that i'd expect it to take no longer than 15 minutes to blast They agreed on the time to undertake the task and confirmed their cost was correct....
i mean like WTF???
So......
having a free morning this morning i stripped it myself.... and the bumper bar is currently cooking in Deox gel...
now the big question? were my cost expectations way off or is my local area just st for getting stuff blasted and powdercoated?
as i dread to think the costs when i get to stripping the underside bits....
Having spent the last 2 weeks trying to find a local to me company which could simply bead blast and powder coat the bumper bar i failed miserably. those i contacted either didn't reply or came back with a stupid cost.
now to be fair i've probably been isolated from being a member of the public, paying retail prices as for many years i've had access to do this simple task through the companies i have worked in and either got it done free of charge or paid a small amount due to the jobs i've put through my various suppliers...
i visited one company and with a straight face they offered to undertake the task for £80.... errr no thanks, i said and walked away shaking my head in utter disbelief.
I then changed tactics and tried finding a company to just bead blast it... found one and good communications from them, how much i asked? £50 please they said, i questioned that they understood the assignment and that it was just for this single piece and that i'd expect it to take no longer than 15 minutes to blast They agreed on the time to undertake the task and confirmed their cost was correct....
i mean like WTF???
So......
having a free morning this morning i stripped it myself.... and the bumper bar is currently cooking in Deox gel...
now the big question? were my cost expectations way off or is my local area just s
t for getting stuff blasted and powdercoated?as i dread to think the costs when i get to stripping the underside bits....
just like a good cookery recipe, painting is just a list of ingredients and cooki... errrrr curing times....
with the Deox having been left overnight after 2 coatings the base metal was almost as good as new, there was one spot on the underside which had slight pitting but i can live with that, considering this piece lives within the bumper cover....
Then 2 coats of Electrox and then high build primer and we have the part now curing....
even had SWMBO come out and comment that it looks good but the funny fecker did also comment that "shouldn't it be black...?" to which i replied yes it should but the black paint i've got on the shelf was the "wrong black".... her look of confusion was priceless as she totted off processing that nugget haha
with the Deox having been left overnight after 2 coatings the base metal was almost as good as new, there was one spot on the underside which had slight pitting but i can live with that, considering this piece lives within the bumper cover....
Then 2 coats of Electrox and then high build primer and we have the part now curing....
even had SWMBO come out and comment that it looks good but the funny fecker did also comment that "shouldn't it be black...?" to which i replied yes it should but the black paint i've got on the shelf was the "wrong black".... her look of confusion was priceless as she totted off processing that nugget haha
and one rattle can of Halfraud's finest satin black later and we have....
i don't normally buy this from there, as i normally have it in stock on the shelf and normally buy UPOL satin black, but i didn't so needs must...!!!
actually laid on quite well and looks quite factory...
of course as i'm anally retentive and a pratt i had to obviously order new fixings from Audi... jesus wept at the cost for 4 sets of nuts and bolts... £25.00.... that's not cheap... but i can't reuse the old rusty ones...
roll on the weekend...
i don't normally buy this from there, as i normally have it in stock on the shelf and normally buy UPOL satin black, but i didn't so needs must...!!!
actually laid on quite well and looks quite factory...
of course as i'm anally retentive and a pratt i had to obviously order new fixings from Audi... jesus wept at the cost for 4 sets of nuts and bolts... £25.00.... that's not cheap... but i can't reuse the old rusty ones...
roll on the weekend...
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