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| D2 - Interior Seats, dashboards, plastics, ventilation everything inside the cabin |
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#1
23rd May 2016, 09:44 AM
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Replacing the passenger side footwell relay cover
After recently bunging up my botang's, replacing my ECU box seal/cover and (hopefully) ridding myself of all other sources of water ingress, I just couldn't bring myself to refit the manky, water-damaged footwell relay cover, so I started looking at ways to replace it.
I've always felt that the choice of materials for this cover, essentially foam-backed compressed cardboard, was pretty poor, so I didn't even bother looking into replacing it with a new one. So I decided to make one ... This was my original cover, a bit minging but in good enough shape to act as a template: After hunting around for suitable material, with ideal criteria such as inexpensive, lightweight, waterproof, insulating, fire/heat resistant and easy to cut, I settled on 10mm 'tile backer board': http://www.ebay.co.uk/itm/221471642769 This particular board was made by Nassboards: http://www.nassboards.co.uk/Insulation-Boards-10-x-10mm Using spray-mount adhesive, I added a thin (about 1-2mm) black foam rubber sheet to both sides then, using the original board as a template, cut it to shape using a knife. As a finishing touch, I added some 12mm wide foam rubber tape around the edge: https://www.amazon.co.uk/gp/product/B00XH8XXBK/ This was the end result, which I'm quite pleased with ... (I added the penny washers to prevent the screws from damaging the foam backing).
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Mark ------------------------------------------------------ 2002 FE S8 Ebony Black Pearl ------------------------------------------------------  ------------------------------------------------------ Cars Owned: The Tesla Era: 2020 Model S Performance Ludicrous+ (present) (Black, with all black premium interior and carbon fibre décor, 21" sonic carbon twin turbine wheels and FSD capability) The Audi Era: '97 A8 4.2 (Ming Blue) --> '96 A8 4.2 QS (Dark Green) --> '02 FE S8 (present) The Citroen Era: '84 BX 1.6 RS --> '89 BX 1.9 DTR Turbo --> '94 XM 2.0L Turbo --> '96 XM 2.0L Turbo Exclusive --> '00 Xantia Activa 2.0L Turbo The Banger Era: '76 1.2L Lada VAZ-2101 (Ruski Fiat 124) --> '80 1.7L Morris Ital HL, finished in Ermine White and Rust Last edited by moltuae; 23rd May 2016 at 10:20 AM. 
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#2
23rd May 2016, 11:39 AM
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Nice job Mark.
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2002 Final Edition S8. Ebony black with Silver Grey leather and myrtle wood trim. Current mods: solar sun roof, 20mm rear spacers, 15 mm on front, red brembo callipers, 6k headlights, rear view camera, engine remap, alloy dash dial rings, alloy navi rings, tt/phaeton pedal upgrade, (and custom matching foot rest) dension ipod interface & parrot hands free kit (both fully hidden), av input, tv in motion switched thro' PF switch in blanking plug right of steering column, Audi 'quattro' sill covers, repositioned centre console switches, radio clock, .Planned mods: auto-dimming rear view mirror, dash cam (as steamship's), fit the ski hatch, refit philips drl's (or maybe not - nope, definitely not - horrible botch!).
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#3
23rd May 2016, 11:41 AM
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Quote:
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Matt 2004 A8 3.7q, 1998 A4 2.8q, 1994 Coupe 2.8q SORN,
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#4
23rd May 2016, 01:14 PM
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Great Job Mark!
Can you make up a load before the annual meet? I'll definitely have one off you - Soul Colour Trim / Carpet please! 
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Confidence is the feeling you have before you know better . . . .  Audi A8 D2 3.7 Quattro Sport 1999 FL - Melange 2nd Place Winner - A8-Freunde Annual German Meet 2012 at Edersee 20" x 9" Bentley GTC Wheels with 385mm W12 Front Discs & Bentley Caliper Covers, Front Lowered on Coilovers, Xenons, Combined DRLs and LED Foglights to modified OEM front fog lamp position, Alcantara/Leather, Full Black Alcantara headlining + pillars and blind shelf, Bespoke Flat Bottomed Sports Steering Wheel, Dark Myrtle Wood, Autodim Mirrors, Bose, Blinds, Digital TV, Ski Hatch, Modified rear exhaust section for extra V8 Burble Audi S8 D2 Final Edition 2002, Avus Silver with Red Leather Interior Tiptronic with Sport mode button, Sony rear entertainment package, Bose sound system, Audi Navigation Plus, 20 inch Final Edition alloys, Full Cat Back Stainless Milltek exhaust, giving a great V8 burble Audi A8L D2 4.2 Petrol with LPG - Ebony Black Audi A8L D4 FL 4.0T Petrol twin turbo - Havana Black Audi A2 1.6 FSi Sport - Dolphin Grey with Votex body kit and Red Leather Interior and some other A8's A8L's and Mercs
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#5
23rd May 2016, 01:32 PM
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 Not bloody likely I'm afraid. It took me about 2 months to find the time to make that one! Also, it goes behind the carpet and mats, so the colour is unimportant. The originals are all beige/cardboard colour. I do have a large piece of Nassboard left, if anyone wants it. Free to a good home (bad homes also considered). There's probably enough to make another 2 covers at least. I've also got plenty of foam rubber tape (for around the edges) but none of the foam rubber sheet left (though that's readily available on Ebay).
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Mark ------------------------------------------------------ 2002 FE S8 Ebony Black Pearl ------------------------------------------------------ ------------------------------------------------------ Cars Owned: The Tesla Era: 2020 Model S Performance Ludicrous+ (present) (Black, with all black premium interior and carbon fibre décor, 21" sonic carbon twin turbine wheels and FSD capability) The Audi Era: '97 A8 4.2 (Ming Blue) --> '96 A8 4.2 QS (Dark Green) --> '02 FE S8 (present) The Citroen Era: '84 BX 1.6 RS --> '89 BX 1.9 DTR Turbo --> '94 XM 2.0L Turbo --> '96 XM 2.0L Turbo Exclusive --> '00 Xantia Activa 2.0L Turbo The Banger Era: '76 1.2L Lada VAZ-2101 (Ruski Fiat 124) --> '80 1.7L Morris Ital HL, finished in Ermine White and Rust Last edited by moltuae; 23rd May 2016 at 01:47 PM.
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#6
23rd May 2016, 04:08 PM
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Very neat. Something I'd thought of doing, but couldn't think what to use of the back. Do you still have the eBay number of the foam backing you used?
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2001 A8 D2 FL 3.7 Q - LPG Conversion, Engine: AKC, Gearbox:FBB, Colour:LY5X Aqua Blue pearl effect, Interior:WJ light beige/dark beige valcona leather with burr walnut inserts My DIY jobs - Replaced alarm horn, Replaced Coolant Temp sensor, Updated RNS-D firmware, Installed Reversing Camera and Digital TV, Dashcam Installation, Retrofitted Rear Blinds, Auto-Dimming Rear View Mirror, Chrome Boot Struts Sold!  2008 S8 D3 5.2 V10 - Engine: BSM, Gearbox:KLW, Colour:LY7F Suzuka Grey Pearl Effect, Interior:Black/Black with Silver/Black valcona leather with carbon atlas inserts, Bang & Olufsen, Heated windscreen, Soft-close doors, TV, DAB, AMI, Quad Zone, Auto Boot, Auto dim Mirrors, Keyless entry, PDC with rearview camera, AFS II HeadlightsMy DIY jobs - Fan Jet Windscreen Washers, Retrofitted Electric Side Blinds
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#7
23rd May 2016, 06:00 PM
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I bought it for something else, over a year ago, and I couldn't find it at the time of posting, but after a bit of digging through old emails, it seems it was Ebay item ID #111227726521: http://www.ebay.co.uk/itm/BLACK-NEOP...-/111227726521 (3mm thick is what I used). I was just using what I already had, although it is very similar to the original foam backing. It's available from numerous sellers it seems and it appears the same stuff is available in a self adhesive form too. Spray-mount adhesive works well though.
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Mark ------------------------------------------------------ 2002 FE S8 Ebony Black Pearl ------------------------------------------------------ ------------------------------------------------------ Cars Owned: The Tesla Era: 2020 Model S Performance Ludicrous+ (present) (Black, with all black premium interior and carbon fibre décor, 21" sonic carbon twin turbine wheels and FSD capability) The Audi Era: '97 A8 4.2 (Ming Blue) --> '96 A8 4.2 QS (Dark Green) --> '02 FE S8 (present) The Citroen Era: '84 BX 1.6 RS --> '89 BX 1.9 DTR Turbo --> '94 XM 2.0L Turbo --> '96 XM 2.0L Turbo Exclusive --> '00 Xantia Activa 2.0L Turbo The Banger Era: '76 1.2L Lada VAZ-2101 (Ruski Fiat 124) --> '80 1.7L Morris Ital HL, finished in Ermine White and Rust
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#8
23rd May 2016, 06:05 PM
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And what do you know, they don't post to Northern Ireland.However, as you say, there are others selling it as well, so it gives me somewhere to start looking. Thanks.
__________________
2001 A8 D2 FL 3.7 Q - LPG Conversion, Engine: AKC, Gearbox:FBB, Colour:LY5X Aqua Blue pearl effect, Interior:WJ light beige/dark beige valcona leather with burr walnut inserts My DIY jobs - Replaced alarm horn, Replaced Coolant Temp sensor, Updated RNS-D firmware, Installed Reversing Camera and Digital TV, Dashcam Installation, Retrofitted Rear Blinds, Auto-Dimming Rear View Mirror, Chrome Boot Struts Sold! 2008 S8 D3 5.2 V10 - Engine: BSM, Gearbox:KLW, Colour:LY7F Suzuka Grey Pearl Effect, Interior:Black/Black with Silver/Black valcona leather with carbon atlas inserts, Bang & Olufsen, Heated windscreen, Soft-close doors, TV, DAB, AMI, Quad Zone, Auto Boot, Auto dim Mirrors, Keyless entry, PDC with rearview camera, AFS II HeadlightsMy DIY jobs - Fan Jet Windscreen Washers, Retrofitted Electric Side Blinds
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#9
23rd May 2016, 06:24 PM
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The image in the ebay listing I posted is misleading, making it look like a rough foam. It's actually very smooth/soft to touch, with a fine/small cell structure, similar to the original foam backing. EDIT: If you can't find a seller who delivers it to NI, let me know, I can order some for you and bring it to the meet (assuming you're going).
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Mark ------------------------------------------------------ 2002 FE S8 Ebony Black Pearl ------------------------------------------------------ ------------------------------------------------------ Cars Owned: The Tesla Era: 2020 Model S Performance Ludicrous+ (present) (Black, with all black premium interior and carbon fibre décor, 21" sonic carbon twin turbine wheels and FSD capability) The Audi Era: '97 A8 4.2 (Ming Blue) --> '96 A8 4.2 QS (Dark Green) --> '02 FE S8 (present) The Citroen Era: '84 BX 1.6 RS --> '89 BX 1.9 DTR Turbo --> '94 XM 2.0L Turbo --> '96 XM 2.0L Turbo Exclusive --> '00 Xantia Activa 2.0L Turbo The Banger Era: '76 1.2L Lada VAZ-2101 (Ruski Fiat 124) --> '80 1.7L Morris Ital HL, finished in Ermine White and Rust Last edited by moltuae; 23rd May 2016 at 06:30 PM.
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#10
23rd May 2016, 06:46 PM
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Managed to find ones that supply to Northern Ireland, so all the bits ordered. That's yet another little job to do to the car now
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2001 A8 D2 FL 3.7 Q - LPG Conversion, Engine: AKC, Gearbox:FBB, Colour:LY5X Aqua Blue pearl effect, Interior:WJ light beige/dark beige valcona leather with burr walnut inserts My DIY jobs - Replaced alarm horn, Replaced Coolant Temp sensor, Updated RNS-D firmware, Installed Reversing Camera and Digital TV, Dashcam Installation, Retrofitted Rear Blinds, Auto-Dimming Rear View Mirror, Chrome Boot Struts Sold! 2008 S8 D3 5.2 V10 - Engine: BSM, Gearbox:KLW, Colour:LY7F Suzuka Grey Pearl Effect, Interior:Black/Black with Silver/Black valcona leather with carbon atlas inserts, Bang & Olufsen, Heated windscreen, Soft-close doors, TV, DAB, AMI, Quad Zone, Auto Boot, Auto dim Mirrors, Keyless entry, PDC with rearview camera, AFS II HeadlightsMy DIY jobs - Fan Jet Windscreen Washers, Retrofitted Electric Side Blinds
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