Today I.....

Well to confirm my fear, the outer edge has a tiny flat, but on spinning the inner is out about 10mm oval. Not impressed.
As much as I like the style they do seem to be made of cheese, the 4 on the car originally were in bad shape, this is one out of a decent set I bought.
Not the best to commute on!
 
Yesterday and today I spent making Diesel drain screw for you nice people. I have been hand turning these for around the last 18 months, but they take a long time to produce and so I have been making in small batches of 4 at a time.
I have for a long time fancied a CNC lathe, but could never justify the cost. Around October time I decided to convert my Boxford Lathe to CNC, plans where drawn up and parts ordered. I made a batch of diesel drain screws and a 24 rollers for the door check straps before I stripped the lathe down.
Its been out of action until a couple of weeks ago when it cut its first metal under CNC control.
All has gone well and the tolerances that it will hold are truly outstanding, far better than I could do manually. As an example I turned 50 brass rollers for the check straps and every roller was exactly the same diameter and length within 0.001", in fact on diameter it was repeating to far greater tolerance in the region of 0.0003" over a same of 10
This was all using a single tool for the face and outside diameter and a separate tool for parting off the rollers
I set about making the drain screws which are some what more complicated as there are multiple diameters and lengths plus a couple of undercuts for the two O rings. Well I was chuffed when the first one come out, every length was spot on, the undercuts where the correct width and all diameters +0.004" (which was what I had aimed for).
Tool offset made and re run the cycle resulting in one finished screw spot on size.
Another 11 where made without a single size adjustments, just refinements to speeds and cutting feeds

So, if anyone needs a drain screw (they fit the TDI's all models from around 2003 inclusive to end of production) you know where to come
49232
49231
49230
 
depronman said:
Yesterday and today I spent making Diesel drain screw for you nice people. I have been hand turning these for around the last 18 months, but they take a long time to produce and so I have been making in small batches of 4 at a time.
I have for a long time fancied a CNC lathe, but could never justify the cost. Around October time I decided to convert my Boxford Lathe to CNC, plans where drawn up and parts ordered. I made a batch of diesel drain screws and a 24 rollers for the door check straps before I stripped the lathe down.
Its been out of action until a couple of weeks ago when it cut its first metal under CNC control.
All has gone well and the tolerances that it will hold are truly outstanding, far better than I could do manually. As an example I turned 50 brass rollers for the check straps and every roller was exactly the same diameter and length within 0.001", in fact on diameter it was repeating to far greater tolerance in the region of 0.0003" over a same of 10
This was all using a single tool for the face and outside diameter and a separate tool for parting off the rollers
I set about making the drain screws which are some what more complicated as there are multiple diameters and lengths plus a couple of undercuts for the two O rings. Well I was chuffed when the first one come out, every length was spot on, the undercuts where the correct width and all diameters +0.004" (which was what I had aimed for).
Tool offset made and re run the cycle resulting in one finished screw spot on size.
Another 11 where made without a single size adjustments, just refinements to speeds and cutting feeds

So, if anyone needs a drain screw (they fit the TDI's all models from around 2003 inclusive to end of production) you know where to come
View attachment 49232View attachment 49231View attachment 49230
Click to expand...

Cracking work sir !
 
Today I fitted 1 replacement door strap to project shed , time required 6 hours ........

It’s turned out to be rather more involved due to the front wing being out of position , and the rear wing fixing being loose ... and to gain access to the fixing involving removing the whole door .... and the wheel arch liner .... etc

This car has been pranged while in the family ownership ,which I repaired , however looks like the wing moved , and the fixing worked loose over the next 4K miles , during this works found out previous “incident “ had been repaired rather badly

The worst part was trying to find out how to remove the door to body wiring harnes plug .. turns out you slide the purple clip forward , and finding out this is not the 1st time the door trim been off....

As always the little jobs, grow rather quicker in to bigger jobs , I used the Audi A2 owner club guide to striping down the door to gain access to the check strap , and @depronman provided his rebuilt check strap for the works .

Rounded the day off with a quick wash and wipe over for Basil
 

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depronman said:
Yesterday and today I spent making Diesel drain screw for you nice people. I have been hand turning these for around the last 18 months, but they take a long time to produce and so I have been making in small batches of 4 at a time.
I have for a long time fancied a CNC lathe, but could never justify the cost. Around October time I decided to convert my Boxford Lathe to CNC, plans where drawn up and parts ordered. I made a batch of diesel drain screws and a 24 rollers for the door check straps before I stripped the lathe down.
Its been out of action until a couple of weeks ago when it cut its first metal under CNC control.
All has gone well and the tolerances that it will hold are truly outstanding, far better than I could do manually. As an example I turned 50 brass rollers for the check straps and every roller was exactly the same diameter and length within 0.001", in fact on diameter it was repeating to far greater tolerance in the region of 0.0003" over a same of 10
This was all using a single tool for the face and outside diameter and a separate tool for parting off the rollers
I set about making the drain screws which are some what more complicated as there are multiple diameters and lengths plus a couple of undercuts for the two O rings. Well I was chuffed when the first one come out, every length was spot on, the undercuts where the correct width and all diameters +0.004" (which was what I had aimed for).
Tool offset made and re run the cycle resulting in one finished screw spot on size.
Another 11 where made without a single size adjustments, just refinements to speeds and cutting feeds

So, if anyone needs a drain screw (they fit the TDI's all models from around 2003 inclusive to end of production) you know where to come
View attachment 49232View attachment 49231View attachment 49230
Click to expand...

Brilliant! Congrats on a job well done. I’ve got a bespoke hand made mark one but I’m very glad these are no longer such a labour.

Ps. I know where to come if I need anything made in metal or otherwise. How about an adaptor plate for an electric motor to A2 gearbox?


Sent from my iPhone using Tapatalk
 
Pinkythelabrat said:
Brilliant! Congrats on a job well done. I’ve got a bespoke hand made mark one but I’m very glad these are no longer such a labour.

Ps. I know where to come if I need anything made in metal or otherwise. How about an adaptor plate for an electric motor to A2 gearbox?


Sent from my iPhone using Tapatalk
Click to expand...
Err just a wee bit to big for my Boxford, however I'm sure over the next 10 years or so it will come
The question is would you still use the gearbox or will it be easier to fit something that drives the rear wheels and stack the batteries /control electronics where the engine and gearbox are currently
 
depronman said:
Err just a wee bit to big for my Boxford, however I'm sure over the next 10 years or so it will come
The question is would you still use the gearbox or will it be easier to fit something that drives the rear wheels and stack the batteries /control electronics where the engine and gearbox are currently
Click to expand...

Hub motors maybe...

I’ll speak to you in 10 years then


Sent from my iPhone using Tapatalk
 
Today I received (Boris’s) Audi badge tape so my job tomorrow is to stick his new badge on ?
49328

If anyone wants any free samples in the future go to my fathers website www.propackaging.co.uk please note it’s not a promotion ?
 
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Yesterday I replaced the coils, as the car had run badly for a couple of months. That fixed the problem, and the engine performs as new again. Another fun thing, when I dropped off the kids at school today, I was approaced by a middleaged man, giving creds to the A2. He had spotted me around town every now and then (I think there are only two resident red Colour Storms in Oslo City Centre) He handed over his business card, and politely asked me to get in touch if I some time in the future were going to sell it. He drove an BMW i3S, and wanted the A2 to join the BMW.
 
Today I received all the service parts for Boris?
49348

Tomorrow he will be getting a full major service. Oil,oil filter,cabin filter,air filter

I’m not going to bother with the fuel filter as that was changed 1000 miles ago so it will still be clean :)?
 
Today I managed to get my locking wheel nuts off by hammering the locking socket onto the 2 remaining bolts on the rear wheels in preparation for all new shoes, drums and wheel cylinders tomorrow. This was due to one locker breaking previously and having to use a lump hammer to drive the socket onto the head to make a new fit!

I’d say don’t use them as the are a nightmare!

c793392169f06c20eaa3a3a6e75a2c60.jpg
 
Cenick said:
Today I managed to get my locking wheel nuts off by hammering the locking socket onto the 2 remaining bolts on the rear wheels in preparation for all new shoes, drums and wheel cylinders tomorrow. This was due to one locker breaking previously and having to use a lump hammer to drive the socket onto the head to make a new fit!

I’d say don’t use them as the are a nightmare!

c793392169f06c20eaa3a3a6e75a2c60.jpg
Click to expand...

They're not genuine Audi A2 ones …

I've got some sets of Genuine ones if you're interested, please see marketplace.
 
Today I changed the #2 fuel injector in hope of solving the misfiring problem that Causes the EML coming on and off for last 3 months. Now the engine is behaving even stranger, EML is back on but showing different fault codes, torque difference and something concerning the thermostat. But the misfiring has gone. The strange behaviours after the injector change includes occasional louder sounds when on load (same sound when starting engine, like a diesel ticking but goes away after few secs). And less acceleration between 2000-3000 rpm, feels like I have lost a few horse power. And oil temp rises beyond 90 as soon as hitting motorway with 3000rpm for 2 mins, had to turn A/C on the cool it down, once it’s on then it dropped and stayed 90, but never happened like that before, it has always been fine driving without a/c, my guess is the new fuel injector is not working well together with the old ones? Reason I only changed #2 because it was only cylinder 2 misfiring and they are not cheap. Should I have changed all 4 fuel injectors? Would appreciate any advice.
 
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