Absolutely Gutted!!

[Alan_uk]

Indeed, and the more I see of this thread, the more I understand why Audi has not followed on with another A2. Most car production is done by robots these days, which allows economy of manufacture, and hence higher profit margins. From the pictures and descriptions in the thread it is obvious that the A2 must have been VERY labour intensive to manufacture (highly skilled labour at that) so I now understand why it was so expensive, and was probably never very profitable. Fascinating thread, and highly educational too.

See attached photo 1 - I see no humans, only robots

2nd photo shows why it was expensive. The space frame consists 225 pieces, cast, machined and (I believe) extruded aluminium, each of which has different properties and needs to be assembled with different techniques (weld, glue, rivets, etc). Whilst that was highly automated it really needed volume to get the payback. But the A2 was not built for volume; it was built (I believe) to refine the production technique for the next A8 model. And anyway, to get volume needed a bigger factory and more investment. The margins were just not there on a small car but are for the more prestigious A8.

There is a very long article with photos on the technical aspects and challenges of building the A2 here:
http://www.audi-sport.net/vb/showthread.php?t=58146

According to the article:

"Audi has also made a major investment in automation, which accounts for a modest 25% of the A8's build but for more than 80% for the A2"

 

[tigas]

That article is just amazing.

 

[ryancooke]

sorry for no updates but my computers b roke and i cannot send pictures to it so it can be uploaded, i am waiting for my bro to come and fix it, meanwhile im on the laptop.

all the panel work is done, and the car is ready for primer, so should be primed tomorrow hopefully, then it will be flatted down, sealed, stonechipped ect, then its ready for paint.

will let you know how it goes

 

[ryancooke]

car has been primed, and is ready for sealing ect then paint, comps still broke so no pics as of yet, hopefully will be able to upload some at the weekend

 

[ryancooke]

car has been prepped, and has been sealed and stone chipped, and the car is all masked and ready for paint (i have also taken the lower half of the tailgate off for paint as it had a small scratch and chip on it) there was also a small dent on the roof pillar which has been repaired aswel as theres no point painting over a dent, so it may get painted tomorrow if there is a painter in, if not it will defo be monday

 

[martings]

great news Ryan
the small pin prick dent on the roof nearthe back quarter was caused by a flying brick thrown up by a lorry about three years ago!
its always annoyed me so happy that will be gone cheers
Any more pics?
Glen

 

[ryancooke]

car is painted inside and out, i have got pics but still cant upload them yet, my bro has just arrived to fix my computer, so will probably be tomorrow and i can upload them.

 

[ryancooke]

PICTURES!!!!!!!!!!

little inner section primed

little panel in

back panel primed

new part primed

rivveted in

 

[ryancooke]

prepped and primed

sealed

car painted!!!!!

only managed to get one pic, will get more from the painted inside aswel on monday for you.

 

[ryancooke]

inside all painted and shiney, bootfloor back in and wires routed

inside trim fitted up

seats back in

the bootlid is on, didnt take a pic thou, then its just the arches, bumper, lights and door to put back on now, then the window bonded in and it all polishing and cleaned then its all ready

 

[martings]

don't forget the mudflaps ha!
Looks good to see it back together.
Just out of interest Ryan why was the door repainted?
cheers mate
Glen

 

[ryancooke]

the new mudflaps are there aswel lol

and the door has to be painted due to blending in the color, as most of the time you can very rarely match a color exactly especially a color like yours. basically a small section of the door will have the color dusted on so it matches with the new quarter panel and the rest is lacquered to give it the shine, thats probably the best way to explain it

 

[ryancooke]

car is basically finished, just waiting on it to be polished, and the window put in, then a few other little bits and bobs, then quality checked, then cleaned.

a couple of pics of how it looked tonight (i well need a new phone, these pics are crap)

incase your wondering about your new o/s/r alloy wheel lol your other one is having a refurb.

 

[martings]

ha i crapped myself then when i saw the rear wheel!
Will it have to be MOT'd?
Also spoke to your gaffer about the roof,assume this will be checked etc
thanks again ryan, it looks great to see it
cheer
Glen

 

[ryancooke]

ha i crapped myself then when i saw the rear wheel!
Will it have to be MOT'd?
Also spoke to your gaffer about the roof,assume this will be checked etc
thanks again ryan, it looks great to see it
cheer
Glen

no it wont have to be mot'd, not unless the mot has ran out ofcourse lol
i had a look at the roof as i was interested in it with the full glass roof, and its fine as far as i know, thanks, ryan.

 

[trufflestu]

Ryan you should be very proud of yourself.

You've done what looks like a sterling job on it.

I've been following the thread since it started, and have looked forward to the updates and the comments you've made as you've worked your way through it.

If mine ever gets shunted (touch wood) I'll demand it comes to you.

 

[dan_b]

Indeed, top work here. Just out of interest, how much has this amount of work cost? It's clearly labour intensive and highly skilled, and doubtless doesn't come cheap.

 

[Meg-A2-91]

Looks great to see her back

 

[murdo]

Ryan you should be very proud of yourself.

I've been following the thread since it started, and have looked forward to the updates and the comments you've made as you've worked your way through it.

I've got to echo truffles comments, this has been a fantastic thread and each set of new photos have been eagerly awaited. A fab job and a great ending to Glen's original misfortune! Thanks a mill for sharing the rebuild with us.

 

[ryancooke]

thankyou very much, its not just me that has worked on the car thou, theres the mechanic/strip fitter (mike) one of the preppers (dave) one of the painters (keith) and a polisher (tom), and also the other people that have helped with the car... estimator, reseptionist's, parts man ect ect the list could go on for quite a bit
i will have a look at the job card to see how much it has cost the insurance company

i havent really got round to looking at the car today, but i think its basically finished, im sure i saw the window in it, and it was out of the polishing bay.

so you should have the car back before the weekend (dont blame me if you dont lol), unless theres parts waiting, but i dont think there is.

oh and try your best not to crash your cars in the next two weeks as i am going to kenya on safari sorry just had to add that as i have been annoying the lads at work for the past month with "are you going to kenya next week........no........must just be me then"