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Brake pads, big brake pads

Written by NEO August 19 2010 at 15:56. Last updated August 19 2010 at 16:02.

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After investigating and researching brake pad part numbers for a good two days I finally ordered a set that I picked up today. My awesome contact at Pagid in USA (thanks Patrick!) helped me to figure out that what I needed was the pads called T1414 on Pagid language. When searching in their online catalog they are linked to these OEM numbers:

PORSCHE, 95535193950        
PORSCHE, 95535193951
VW, 7L5698151
VW, 7L0698151

My conclusion after googling for those numbers for a few days was that 955 351 939 50 was what I needed and my Pagid contact came to the same conclusion. The odd thing is that even though I ordered 955 351 939 50 what I got was 955 351 939 51 and the later is supposed to have totally different measurements, according to my search results. A bit worrying but the pads fit and all looks ok and the measurements are ok so I guess it's the correct pads. Not sure what to do with the springs that I have for the mounting kit though. They are used when these calipers are used with ceramic pads, as seen in this picture, but the pads I got now don't seem to need those springs.

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Template for logo on front caliper and rear splash shield

Written by NEO August 14 2010 at 18:57. Last updated August 14 2010 at 18:57.

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Another productive day in the garage. I started with making a cardboard cutout of the front face of the caliper, I'll need it when I make the custom logo for them.

I also started to look at the rear splash shields. I got an original splash shield with the wheel hub assembly I bought and I sacrificed that one today. I also had to use the angle grinder on the RS4-splash shields I bought a few year back, always funny to put the grinder in brand new stuffs. =/ Anyways, looks like I'm on too something and I just need to tidy it up a bit and weld it together and put some new paint on it. Oh, and of course make the other side too. =)

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Blasted front brakes and grinded Phaeton splash shield

Written by NEO August 13 2010 at 18:56. Last updated August 13 2010 at 19:13.

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I picked up the front brakes from the blaster today and wow, he did an excellent job! He had blasted them with aluminum oxide and apparently it took a while for him but the result is awesome. Now I have to figure out what to do with the paintwork but that's a later story/post.

I also picked up the brackets from anodization. They came back a bit spotty and according to the guys that anodized them that's because some of the compounds in the 7075 aluminum reacts with the anodization process. It looks almost like small spots of oxidation. I'm honestly fine with it since they will be dirty all the time and nobody will really ever seen them, I just want them somewhat protected from mother nature and not to obvious and visible for the MOT guys.

The work on the Phaeton splash shields have continued today. Seems like it was a bit more difficult then first anticipated. As seen on the pictures I decided to remove the reinforcement for the air scoop so now the splash shield looks like a Swiss cheese.  The idea is to weld a 1mm sheet metal that's cut out to fit the S2 to the Phaeton splash shield, and then weld the reinforcement for the scoop back onto it. I'm not totally convinced that this will work but it's the path I will take but I have started to think out a backup plan.

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Moving on with the brakes

Written by NEO August 11 2010 at 20:55. Last updated August 11 2010 at 21:03.

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This week I have had some time to work on the brake upgrade. I prepared the "ceramic" calipers for glass blasting and I took a good look at the 'Audi ceramic' logo on the calipers to see if it was painted or a sticker, seems to be painted. The calipers are at the blasting shop now and I hope to get them back late this week or early next week. I have bought black Foliatec paint that I will paint them with and now I just have to figure out how to get my custom logo onto the calipers, sticker or paint...? I have also left the caliper brackets for anodization.

For the rear brakes I bought an extra wheel hub assembly from a scrap yard to make this build a bit easier. I immediately noticed why the carriers wasn't aligned correctly with the discs. As seen on the pictures I had to grind some material of the carriers to make them sit properly on the S2. Once this was done I started to play with different distances between the hub and the disc until I got the disc centered in the carrier, it seems like I must space the disc out 7 mm. The plan is to have a new hub manufactured so I don't have to use a separate spacer.

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Sensors, sensors, sensors... All these damn sensors!

Written by NEO August 06 2010 at 21:37. Last updated August 07 2010 at 10:53.

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...time did tell if it worked or not, it didn't. All the fault codes came back and to recap they were:

00561 - Mixture Adaptation, 13-00 - Adaptation Limit (Mul) Not Reached
00281 - Vehicle Speed Sensor (G68), 03-00 - No Signal
00537 - Lambda (Oxygen Sensor) Regulation, 11-10 - Control Limit Not Reached - Intermittent

I asked around on http://www.s2forum.com and the friends over there said that I had to replace the lambda sensor. I was a bit skeptical since most of the google results indicated that it could be enough with cleaning the MAF. But I wanted to rule out the lambda sensor so I bought a new one and replaced it and guess what, for now the 00537 and 00561 fault codes are gone. Those chaps over at http://www.s2forum.com rocks. =) But, since it was an intermittent error I will not claim victory just yet though. As seen on the pictures the MAF for sure could need some cleaning too but I couldn't get my hands on any isopropanol today. =/

I kinda ran out on ideas about that vehicle sensor fault code and the only thing left was to take the instrument cluster apart and clean all connectors. And for now that actually seems to have done the trick. But also this was an intermittent error so it's too early to really say if it's fixed or not but at least the code is gone for now.

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Sensor thursday.

Written by NEO July 15 2010 at 17:05. Last updated July 15 2010 at 17:46.

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I have been having some issues with the onboard computer and the cruise control so I decided to take a look if there were any stored fault codes. And yes, there were a few...

3 Faults Found:
00516 - Closed Throttle (Idle) Position Switch (F60), 30-00 - Open or Short to B+
00561 - Mixture Adaptation, 13-00 - Adaptation Limit (Mul) Not Reached
00281 - Vehicle Speed Sensor (G68), 03-10 - No Signal - Intermittent

00516 and 00561 was a bit unexpected and I hope that 00561 was a result of 00516 and nothing serious. 00516 was just like it says, the throttle position switch (F60) that needed an adjustment and it was a fairly easy fix. I just released its two screws and rotated it, with the throttle closed, until I heard the switch in it go "click" and at that position I fastened the screws.

00281 was the one I was after since it affects the onboard computer. It turned out that I had a spare G68 on my old gearbox so I studied that one and looked at how it was mounted but I never used it. Once I had it figured out I removed the G68 from my current gearbox and I cleaned it up and sanded the connectors to remove any corrosion and dirt that could cause an "intermittent error". I reassembled everything and made sure that there was no fault codes and I guess only time will tell if it works or not.

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Summer update

Written by NEO July 14 2010 at 00:11. Last updated July 15 2010 at 17:45.

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The whole ceramic brake disc deal made me lose the interest for the car for a while. So nothing have really happened with it during the winter. I have posted a few random pictures of it where the last ones display my newest problem. A red BMW was sanded down in our garage during the winter. Apparently there was still dust floating around in the garage and when I took it out for a spin a week ago I never noticed the thin layer of dust on my car. During the day when the car was parked the red particles burnt into my paint so now my roof and hood are red metallic. =( Don't really know what to do about it at the moment, it just sucks so hard. =(

In other news I have sold my 18" Cup 3 replicas and I have bought a rear wheel hub with assembly that I can use when working with the rear brakes, hopefully this year. =)

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They came, they sucked, they left... The ceramics!

Written by NEO July 13 2010 at 23:12. Last updated July 14 2010 at 18:29.

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I have not posted about the ceramic brakes yet, actually I haven't posted much at all for a while. There's a good reason for it and that good reason is called district court. The brakes that I bought from someone that I considered to be a friend, at that time not any longer, had some serious damages and was not at all as the seller had described them. First of all both the calipers and the discs were really poorly packaged and the calipers had moved around freely in the box and leaked brake fluid all over the place. Also the discs had loads of space to freely move around in the box, not exactly how you ship stuffs like this! The discs were said to have small dents on the edges from stones and normal usage. But both discs had huge damages and were for sure not safe to mount on a car. The seller refused to take them back and give me my money back and first when I turned to the district court he agreed to buy the brakes back. Sadly I had left my RS4-b7 brake kit as part of the payment and he had already sold that on to someone. =/ But atleast I got a sum back that covered the total value of the deal but I still lost a lot on it since I had to pay the legal expert I'd hired. =( It's a sad story and I had to shorten it down here so I wouldn't bore you out. Now I will use my other ceramic calipers and the 380mm MTM steel discs instead.

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New brakes, again.

Written by NEO November 10 2009 at 06:38.

Yeah I know... I'm a moron. But I couldn't resist to buy this set of brakes. Once again it's the 6 pot "ceramic" calipers but this time with ceramic discs and brake pads! The black RS4/RS6 8 pot caliper was traded in as a part of the deal and the 6 pot with the 380mm MTM steel discs is for sale.

I will post pictures once they arrive. So is this the first street S2 with ceramic brakes? =)))

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Custom rear bumper, RS2-style

Written by NEO September 06 2009 at 20:41.

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This have been in the works on and off since 2005 or something. Thought I should dust it of and hand it over to a manufacturer I can finalize the damn car sometime. There's shitload of work left on the bumper though. =/

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