We still remember the first drive — a worn coupe that handled Lake Tahoe snow and chased weekends at the track. That memory fuels this project and explains why care, patience and clear planning matter when you tackle a classic car build.

This is the story of a 1984 quattro rebirth, moving from black sheep to white swan through a bare-chassis rebuild and thoughtful upgrades. We outline the scope from inspection to delivery so you can see when to commit time and budget.

Expect a cohesive plan that sequences engine and turbo work, paint and interior updates, chassis preparation and systems integration. The goal is period-correct looks with modern reliability and spirited driveability for long Australian runs and weekend use.

For context on pedigree and historic references, see the documented works car history here: classic works example.

Key Takeaways

• Structured planning saves time and avoids costly rework.
• Sequence engine, body, interior and systems for an efficient build.
• Respect provenance while adding smart, reversible upgrades.
• Chassis and interior prep shape the final driving feel.
• Quality services and experienced hands keep the project on track.

Project brief and initial assessment: from Black Sheep to White Swan

We began with a well‑used 1984 coupe that had spent years on snowy roads and track weekends.

Our first task was a measured inspection. We checked the chassis, seams and underbody for creeping rust and noted dents across panels.

We set the brief around a hard‑used rally‑bred coupe. That meant the car needed structural attention, not just cosmetics, to be safe and reliable for day trips and the occasional track session.

Starting point: condition and use case

The owner uses the car for weekday commuting, weekend runs and the odd track day. That balanced use informed a plan that keeps comfort while sharpening response.

Identifying problem areas

• Documented surface rust and fender dents, with panel gaps mapped for metal work before paint.
• Catalogued wear on bushings, lines, electrics and consumables to decide what parts could be saved or require refurbishment.
• Sourced strategies for NLA components and agreed a shop plan to restore original items to as‑new where possible.

Baseline testing captured noises, vibrations and brake feel. These notes set measurable goals for repair and helped the shop schedule work across the year with risk allowances in place.

Bodywork and paint: bare chassis prep to colour-change perfection

We stripped the shell to bare metal so every dent, seam and hidden corrosion could be found and fixed.

We began with a full strip so the car’s panels could be straightened properly. Hidden rust in seams and the chassis was treated early to stop spread and costly follow‑up work.

Metal, seams and panel shaping

The team reshaped panels and repaired metal where needed. Panel alignment was checked repeatedly during the job so gaps stayed consistent and the finish laid flat.

Underside, cleaning and mid-body prep

The underside received a pressure wash to clear years of grime before drivetrain removal. This cleaning ensures refinishing systems bond correctly and last the year ahead.

Prime, seal, wet sanding and off-car painting

A disciplined process of multi-stage prime, seal and wet sanding set the foundation for a seamless colour change. Doors, bonnet, bumpers and decklid were painted off the car to protect edges when things go back together.

• Protective masking: the shop used strict masking during assembly to safeguard fresh paint from tools and fasteners.
• Finishing touches: new glass and a black tail-lamp group complemented the colour swap while keeping the look period-correct.

Result: Time invested in this work pays off later. Well-prepped surfaces resist chips, make regular care easier and keep the car looking right for many drives to come.

audi 80 quattro restoration powertrain: AAN 20v turbo five and RS2 breathing

We rebuilt the powertrain around a strong AAN 20‑valve five, chosen for its torque and tuning headroom.

We removed the engine to refresh the bottom end and the head. New bearings and connecting rods were fitted and the head was rebuilt for reliable sealing and longevity.

Engine mounts, brackets and accessory updates

Mounts and brackets were replaced or refinished and painted before reinstallation to control movement under torque and cut NVH.

The accessory drive was modernised with a 2B serpentine system and an updated alternator for steady electrical output.

Intake, intercooler and exhaust

RS2 intake and exhaust manifolds improve flow and throttle response. A 2B intercooler keeps intake temperatures down under load.

A true 3‑inch turbo‑back exhaust with twin O2 bungs and thick flanges reduces backpressure and aids tuning.

Oil control, cooling and brake assist

Oil baffling was added to the sump to prevent pickup starvation during hard cornering and track use.

Cooling was upgraded with a 4‑row aluminium radiator, 2B carbon fibre shroud and a 500W fan with full perimeter ducting to maintain stable water and oil temps in hot conditions.

The hydraulic booster was converted to a vacuum brake assist system to improve reliability and reduce parasitic load on the engine.

• Benefit: stronger mid-range power and cleaner top‑end pull with controlled temps.
• Outcome: predictable drivability and durable parts for daily use and spirited runs.

Chassis, suspension and wheels: handling that matches the legend

Handling was a priority, so we rebuilt the underpinnings to deliver predictable control and feel.

We refreshed the chassis by fitting a restored rear subframe with 2Bennett bushings and a matched swaybar kit. This returns crisp geometry control and cuts unwanted movement under load.

Suspension changes included height and rate adjustable coilovers. That lets the car be set up for Australian roads or the odd sprint event. Alignment specs were matched to the intended use.

• 2B adjustable camber/caster mounts for precise tyre contact patch control.
• Front and rear shock tower braces to improve steering precision and mid‑corner stability.
• Inspection and renewal of related arms, fasteners and studs to keep the system tight.

Wheel choice matters. Period‑correct Fuchs were stripped, machined, refinished, polished and clear coated. They were mounted on 2B studs and nuts to deliver strength and authentic looks.

Outcome: corner weights and rake were finalised for a dual‑purpose build. The package preserves steering feedback and traction while filtering harshness through compliant mounts and bush parts.

Interior, electrics and systems integration: OEM+ comfort for road and track

We treated the cockpit as a priority, blending practical upgrades with careful preservation.

First, the wiring loom was fully overhauled to marry the original circuits with the upgraded engine harness and new systems. The job avoided clutter behind the dash so the car starts, charges and cools consistently.

Wiring overhaul and controls

Late‑style differential lock controls were relocated above the driver’s left knee for ergonomic access. The freed bay now hosts three clear gauges for oil, boost and water temperature.

Seats, shelf and trim

We fitted Recaro power front seats and trimmed custom rear seats to match. The rear shelf was rebuilt in fibreglass, then recarpeted and fitted with fresh speakers for a durable, factory‑looking finish.

Systems and final integration

• Air‑conditioning was integrated with the accessory drive so the cabin stays cool on hot Australian runs.
• 2B wiring supports the 500W fan and cooling shroud, and the intercooler plumbing was routed cleanly.
• We staged interior services after body work in the shop to protect trims as the car goes back together.

Result: a tight, usable interior that supports daily driving and the occasional track day without losing period charm.

Conclusion

The finished build pairs classic lines with upgraded systems that invite both road and track days.

We delivered an organised, usable coupe that blends RS2 manifolds, a 2B 3‑inch turbo‑back exhaust and a tuned intercooler with a 4‑row radiator and 500W fan. The engine and turbo now pull cleanly, with oil control and cooling sorted for repeat laps or long runs.

The paint, straight panels and tidy interior show the value of doing the job once and doing it right. Suspension, wheels and brake work give a planted feel that suits new and experienced drivers alike.

Reliability upgrades and thoughtful parts selection let the owner skip a GT3 and take this car to the track. This quattro restoration proves careful planning, skilled services and measured repair deliver lots of usable performance at the end of the project.