Extreme Cars Owners Club - Kitcar UK zxrjohn14 360 build
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Read November 28, 2018, 04:38:54 PM #30

Re: zxrjohn14 360 build

Cheers Chris,

The main thing is the plenums, I can build everything else from the different car parts.

Read November 28, 2018, 06:31:57 PM #31

Re: zxrjohn14 360 build

just a thought here, but does anyone know if there is a reason the Audi window regulator can't be used?
both Audi and Pug items are 8 pin and thought it would be easier to rewire than do the plate and bush thing.
Read November 29, 2018, 10:38:51 AM #32

Re: zxrjohn14 360 build

is it not because the window has to slightly rise once door is shut ?
Read November 29, 2018, 02:22:48 PM #33

Re: zxrjohn14 360 build

is it not because the window has to slightly rise once door is shut ?
This would be done via an ecu or the vehicles programming, the motor itself is just 12v one way and 12v the other to make it go up and down, so wouldn't matter what is on the end of the wires, so long as it was wired correctly. I'm not sure why there is 8 pins on each, but sure the'd be for similar things on both cars, as the motor units are actually the same make. (i could be completely wrong though)
speaking of which, has anyone got a pinout of the 8 pin connectors, or wiring diagrams of the Pug and the Audi? I'm struggling to find them online.
« Last Edit: November 29, 2018, 02:56:55 PM by zxrjohn14 »
Read December 06, 2018, 07:06:43 PM #34

Re: zxrjohn14 360 build

right, here we go, Audi a3 window mod part deux
I've got them fitting perfect, and i mean perfect without much modifying to the roof......I feel the need to point out that there is no 'modifying' to the roof. When i have read this in other places, the way my brain works (i'm a black or white kinda guy) modifying means serious work, its not, you twat the bits of metal that hold the door rubber trim backwards or forwards to match the shape of the glass. i've also cut the extreme metal plate that meets at the top corner with the roof and bent it forward to the same line as the pug roof bit that holds the door rubber, so the door seal flows around better, it also helps with thew shape of the glass. i've also packed this part of the rubber down to meet the glass, i used 20mm plastic packers diminishing down from 5mm to 1mm in 40mm steps, this brought the rubber down to the exact shape of the glass.
With the frame, i've fixed it in each corner to hold it in place and the bolts are accessable incase it needs to come out to replace a broken window or anything, the back of the pug door will need to be cut again, but at least it's not impossible.
now the motor swap....with pictures!
There is plenty on here and other places about taking the 2 motors apart and whats need, so i won't mention that too much.
Thanks to dads360 for explaining it on his thread to me, and this is how i interpreted it.

esential kit, please note the long m8 bolt

cut the audi spline off here

i put the pug cog in a vice, small cog down

Then cut the big cog off leaving a square, i also put a few little slits in

get one of these

and heat the bastard up to red hot

put the m8 bolt through, grab the end of bolt and trap head of bolt in vice, be quick as the bolt gets hot. Don't heat the bolt up as the plastic will melt and your plastic bit will end up wonky......no one likes a wonky bit
wear a mask or cover your nose as the burning, melting plastic stinks and burns the top of your nose when breathed in...i know this now from experience

shove the cut off spline bit of plastic from the a3 motor on and push down with a 12mm spanner to meet the remaining cog

knock the bolt out

and put the remaining cog bit back into the pug cog shaped bit on the motor

make an adapter plate to bolt onto the audi bolts (i made a template from paper) and cut the 3 audi inserts off the motor so as to leave 12mm sticking out to fix the plate to. please ignore the holes for the pug motor, i changed my mind due to resticted access

drill 3 of the 4 mounting holes through on the pug motor, put the new added spline into the audi splne hole, drill through the mounting holes, tap the plate and hey presto...its fitted

« Last Edit: December 06, 2018, 07:13:48 PM by zxrjohn14 »
Read December 06, 2018, 08:34:51 PM #35

Re: zxrjohn14 360 build

Wow . Looks like you've smashed it mate . Well done great work .

And all working fine with doors shut ??
Read December 06, 2018, 09:02:40 PM #36

Re: zxrjohn14 360 build

Everything works perfectly. The glass sits behind the rubber bit and seal correctly, when the door glass goes down on door opening (10mm) it comes out of the rubber and clears on opening. It couldn't be better for a Peugeot cut down to be a Ferrari rep using Audi glass  Cheesy
I'm very pleased  Grin
Read December 06, 2018, 09:31:26 PM #37

Re: zxrjohn14 360 build

Great write up John
I am sure it will help out others on this subject
Watch the price of Audi windows rocket now haha
Read December 06, 2018, 09:49:34 PM #38

Re: zxrjohn14 360 build

I might start stockpiling them  Grin
Read December 08, 2018, 02:00:40 AM #39

Re: zxrjohn14 360 build

did you use the audi spline?? i remember JD had them custom made... great skill there mate!
Read December 08, 2018, 07:29:32 AM #40

Re: zxrjohn14 360 build

Yes, used the audi spline and melted it on to the Peugeot motor sprocket.
The only thing to make is the plate to fix to.
Read December 09, 2018, 08:26:33 PM #41

Re: zxrjohn14 360 build

Impressive, also delighted to see its possible to achieve wthout roof mods.
Wonder if its possible without having to take the GRP door skin off.
Read December 09, 2018, 10:59:21 PM #42

Re: zxrjohn14 360 build

In all honesty, I'd say yes, but it'd be a faff and difficult, but far from impossible.
Read December 10, 2018, 07:16:28 PM #43

Re: zxrjohn14 360 build

A few more updates

Insulated the inside of the door, and prepped the top ready to spray black

Finished the clocks off

Shutzed everything!

And insulated the rear bit

Read December 21, 2018, 09:52:55 AM #44

Re: zxrjohn14 360 build

I've had an hour or so here and there on the car and fitted a few bits internally

new steering wheel, OMP and OMP boss

MDF box under the two seater conversion (This is Kev's idea and i nicked it)

Covered, speakers in and cargo net fitted


Behind covered

My seats

the chosen leather for door cards and two seater bit

wiring getted sorted in the roof skin and things getting fitted, this will be covered in black head liner

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