Audi 80/S2/RS2 door card refurbishment

Started by RS ZWEI, March 04, 2015, 02:19:33 PM

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RS ZWEI


With the vinyl (not leather - cheap Audi!) lifting on the RS2 I decided it was time to get it sorted (I guess this would be the same as a 80 or S2). On my car it seems to have lifted where the pressure points are on the door - where your arms and hands press on them.
Anton has given me some tips so here I go . . .

I thought I would start with the rear door for two reasons.

1) It was in the worst condition

2) It had a smaller and more simple vinyl shape



Ive had one of the front door cards off before, and would say they are easier to remove than the rears.

Here are the screws you need to remove:






(screw behind the door pull/lever)


(screw holding the door pull/handle together) Which once removed reveals these two screws:



You then slide the door card up, not out. But you also have to disconnect the door pull/lever, speaker wires and window winder plugs.
1980 VW Golf GTI Track Car
1995 Audi RS2
2003 Mini Cooper S (Written off - rear ended)
2005 Mini Cooper S
2006 Skoda Octavia vRS Combi
2009 Renault Megane 230 R26 (Written off - rear ended)
2013 Renault Megane RS265 Redbull RB8

RS ZWEI


Once the door card was off I removed off the carbon trim:



To remove it all I all you have to do is flick these sliders off:



I had an issue removing an aftermarket tweeter (in the factory location). I had to remove the tweeter from its housing out the front so I could access the screw so I remove the mount:




1980 VW Golf GTI Track Car
1995 Audi RS2
2003 Mini Cooper S (Written off - rear ended)
2005 Mini Cooper S
2006 Skoda Octavia vRS Combi
2009 Renault Megane 230 R26 (Written off - rear ended)
2013 Renault Megane RS265 Redbull RB8

RS ZWEI


The next stage is to remove the vinyl by rolling it off, then I got a plastic scraper and a brush with stiff bristles:





I have to decide on what thickness foam to use. 5mm or 10mm?
1980 VW Golf GTI Track Car
1995 Audi RS2
2003 Mini Cooper S (Written off - rear ended)
2005 Mini Cooper S
2006 Skoda Octavia vRS Combi
2009 Renault Megane 230 R26 (Written off - rear ended)
2013 Renault Megane RS265 Redbull RB8

weta.worker

Nice!

Mines in the process of getting the cards redone (I'm upgrading to leather).

Car is still about 1.5 weeks away (according to the shop)

+ another few days to go back to Powerhaus to get a warrant

:D
1994 RS2 GUARDS RED
2001 RS4 NOGARO BLUE

Stanceking

Id say 5mm would be thick enough, Ive still got to do this for both of my 80's so let me know what you use
1983 500sec

RS ZWEI

Quote from: Stanceking on March 04, 2015, 05:01:13 PM
Id say 5mm would be thick enough, Ive still got to do this for both of my 80's so let me know what you use

I think Anton recommend 10mm as he used 5mm.
1980 VW Golf GTI Track Car
1995 Audi RS2
2003 Mini Cooper S (Written off - rear ended)
2005 Mini Cooper S
2006 Skoda Octavia vRS Combi
2009 Renault Megane 230 R26 (Written off - rear ended)
2013 Renault Megane RS265 Redbull RB8

ranton-inc

#6
5mm is ample. I looked at the 10mm again.. its probably a bit too thick.

Also get your hands on some 3M High Strength 90

Its a spray contact adhesive that is super easy to work with and sticks like damn... its just expensive  but worth it.

RS ZWEI

Quote from: ranton-inc on March 05, 2015, 05:33:51 AM
5mm is ample. I looked at the 10mm again.. its probably a bit too thick.

Also get your hands on some 3M High Strength 90

Its a spray contact adhesive that is super easy to work with and sticks like damn... its just expensive  but worth it.

I think you are right in regards to 5mm.
1980 VW Golf GTI Track Car
1995 Audi RS2
2003 Mini Cooper S (Written off - rear ended)
2005 Mini Cooper S
2006 Skoda Octavia vRS Combi
2009 Renault Megane 230 R26 (Written off - rear ended)
2013 Renault Megane RS265 Redbull RB8

le mans

#8
Regarding your Q in the other thread, when my vinyl started lifted I glued it back down using F2 contact adhesive. Seems to be holding up ok.

RS ZWEI

Quote from: le mans on March 05, 2015, 08:19:10 AM
Regarding your Q in the other thread, when my vinyl started lifted I glued it back down using my contact adhesive. Seems to be holding up ok.

OK.
Its the foam that it breaking down rather than the vinyl lifting.
If its working for you thats cool.
1980 VW Golf GTI Track Car
1995 Audi RS2
2003 Mini Cooper S (Written off - rear ended)
2005 Mini Cooper S
2006 Skoda Octavia vRS Combi
2009 Renault Megane 230 R26 (Written off - rear ended)
2013 Renault Megane RS265 Redbull RB8

le mans


Quote from: RS ZWEI on March 05, 2015, 08:25:47 AM
OK.
Its the foam that it breaking down rather than the vinyl lifting.
If its working for you thats cool.
All good, just an alternative option if the foam is holding up ok.

RS ZWEI

Im going to use the 5mm foam. I kinda wonder 7.5mm would be best, though I dont think you can get it?

So I think Im going to glue the foam down first, want for it to set and then glue the vinyl down? What do you think?

1980 VW Golf GTI Track Car
1995 Audi RS2
2003 Mini Cooper S (Written off - rear ended)
2005 Mini Cooper S
2006 Skoda Octavia vRS Combi
2009 Renault Megane 230 R26 (Written off - rear ended)
2013 Renault Megane RS265 Redbull RB8

RS ZWEI

#12
The next stage was to tape the area up better so I dont get any glue over spray.



The method is to spray the foam and seal it both sides. This was recommended on the can if the material is porous. You then let it set.



Next you spray both surfaces you are gluing together. But you let it sit and go to tack for between 5-10 mins. Then line it up and firmly push it together. You only really get one shot at this.
 
1980 VW Golf GTI Track Car
1995 Audi RS2
2003 Mini Cooper S (Written off - rear ended)
2005 Mini Cooper S
2006 Skoda Octavia vRS Combi
2009 Renault Megane 230 R26 (Written off - rear ended)
2013 Renault Megane RS265 Redbull RB8

RS ZWEI

1980 VW Golf GTI Track Car
1995 Audi RS2
2003 Mini Cooper S (Written off - rear ended)
2005 Mini Cooper S
2006 Skoda Octavia vRS Combi
2009 Renault Megane 230 R26 (Written off - rear ended)
2013 Renault Megane RS265 Redbull RB8

le mans


le mans

How is this holding up Nik? Have you had a go with the front door cards yet?

RS ZWEI

Quote from: le mans on June 28, 2016, 11:23:17 AM
How is this holding up Nik? Have you had a go with the front door cards yet?

Yeah, not that great. It started lifting around the edges.
1980 VW Golf GTI Track Car
1995 Audi RS2
2003 Mini Cooper S (Written off - rear ended)
2005 Mini Cooper S
2006 Skoda Octavia vRS Combi
2009 Renault Megane 230 R26 (Written off - rear ended)
2013 Renault Megane RS265 Redbull RB8

le mans

That's a bummer. My repair isn't doing too well either. Might need to get it done professionally.