The Project

Loads of little jobs done over the last few weeks…

First off… Re-routing and securing of the boot release cable. I’ve no longer got a key barrel in the boot lid, but I still want to ensure the boot is not solely reliant on boot springs to keep it secure.

I also begin drilling the front fenders to fit the headlamps. This was much easier with the little tool I made for ‘blindly’ finding the holes behind the fenders.

I then modified the headlamps by removing the obsolete OEM grill locating tabs. This is an actual S5 mod required to make them fit with an S5 bumper.

Finally I mounted the badge holder which has two M6 rivnuts mounted in to the bumper bar underneath the bumper…

Loads more to come!

#555

Following on from the last post, here’s the mounting of the two support brackets.

With the front fenders and front bumper fully mounted, the new mounting plates and brackets were offered up in their final position - marked up and clamped.

Then the mounting plates were tacked in place and the brackets bolted on and the fenders and front bumpers drilled for bolting them in place, by using an M6 rivnut in the bumper sides.

Final welding of the mounting plates will happen later on when it’s back on the rotisserie.

Countless hours of work, but happy with the outcome 😁

#555

Okay, so this one’s not an S5 specific part, but I’ve been tormenting myself for months trying to come up with a solution for brackets to support the front of the fenders and the sides of the front bumper.

I weighed up loads of options… some proved too complicated to make and would not have been quite as supportive as the final design I ran with.

This was an absolute pain to develop… I had specific place that it needed them to mount on the inner flitch, but this meant they needed to drop down 20 degrees and offset backwards to meet the fender/bumper mounts… and I wanted it to have a solid mount for the twintex liner too. I also didn’t want holes going through the inner flitches to bolt them to, so came up with some captive mounting plates to weld on, that they’ll mount to.

The usual countless hours of taking dims, CAD work, card templates and then final laser cutting…. Followed by some difficult folds to get right, welding… etc etc.

Another massive rabbit hole to have gone down and I appreciate they are completely over-engineered… but they do the job and look well.

More to follow on mounting them to the shell...

#555

Another 1997/98 S5 specific part designed up and fabricated over the last couple of weeks.

These are the rear ventilation components that run from the parcel shelf to the rear pocket for drawing out hot air from the cabin.

There are two main parts… the 2.5” duct that is riveted to the underside of the parcel shelf and the cowl that attaches to the OEM plastic vent in the rear pocket.

Lots of time spent spec’ing this up in CAD before being laser cut, shaped, welded and then dry fitted to the shell.

#555

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#555