Technical Features
Project DIY RS4 (B5): Rear Body Panels
By by: JJ Larson and George Achorn, photos by JJ Larson
Apr 13, 2007, 07:11

Converting an S4 to an RS4 visually is no easy task. It’s not simply a matter of changing out the bumpers or tacking on some body kit pieces. B5 connoisseurs will quickly tell you that the RS4 had unique quarter panels, sideskirts, bumpers and more – an intricate mix of parts that created a wholly different look. It’s a big job, and one we’ve decided to break up into key areas as we move along.

Sourcing the parts is not easy. Finding a list of parts was a big task, and then finding a source is even more intensive. American or European, most parts counter guys at a dealership will look at you cross-eyed if you ask about getting a list of parts to convert a car. When we converted our Project B6 A4 1.8T Avant to S4 spec body, it was a similar problem, and would have never gotten through it without a friend who’d done it before guiding us along. This was no different, and a friend of the car’s owner both knew the parts needed and was able to source them. Without him, this project likely wouldn’t have happened, and better yet, he’s willing to source conversion parts for others as well. Simply email the car’s owner JJ Larson for details and he’ll put you in contact.

Expect to pay over $7,000 for the parts alone (price based on current exchange rate and pricing from the dealer) plus shipping from Europe. This is no easy task, but as you can see in the pictures, really transforms the car.

Parts sourced, it was time to set about cutting, grafting and installing in an effort to bring the body of our S4 donor up to the sculpted look of an RS4. Our car was transferred into the skilled hands of Mayer’s Autobody in Little Ferry, NJ for the next stage of the transformation.



Perhaps the hardest section to install is the rear quarter panel. On an Avant, replacement of this panel requires the removal of the rear quarter glass. Further, the OEM RS4, the panel extends up the D-pillar and along the top of the window to the C-pillar. In an effort to minimize the removal of factory welds, our existing panel and replacement were cut half-way up the D-pillar – easier to seam on the flattest part of the D-pillar’s center.



To achieve the initial fusion of the RS 4 quarter panel to our stock sheet metal, it was necessary to weld at the aforementioned point on the D-pillar. After the weld, the D-pillar was ground smooth and body filler applied, awaiting finishing.



At the wheel wells, it was necessary to remove the arch as the stock interior of the wheel well would have caused clearance issues for the car’s widened stance. Some modification was necessary to mate the stock RS4 quarter panels to the existing stock interior quarter in order to create an air-tight joining of the two layers.



In order to achieve this, the wheel well interiors must be widened in order to connect the two panels – an OEM fit we were looking to replicate. Metal was added in this area and seam sealer applied. When finishing touches have been made to this area, undercoating will be applied to the wheel wells in an effort to protect the new metal and joining points of the wheel wells.



Using all OEM parts may be expensive, but it is usually well worth it. The rear quarter panel in place, the rear doors were also installed, aligning perfectly with the new RS4 skin and RS4 sideskirt.

As you can see, our DIY is now transforming rapidly. In our next installment, we’ll be entering the primer stage, including separate pieces such as doors, bumpers, fenders, skirts, etc.

MORE INFORMATION:

Project DIY RS4 Main Page email: JJ Larson Shop Used: Mayer's Auto Body Little Ferry, NJ 2016414303 Parts Used: L ROCKER TRIM R ROCKER TRIM L REAR DOOR SHELL R REAR DOOR SHELL L FRONT FENDER R FRONT FENDER FRONT BUMPER COVER REAR BUMPER COVER L FOGLAMP R FOGLAMP L FRONT BUMPER BRACKET R FRONT BUMPER BRACKET L REAR QTR PANEL R REAR QTR PANEL FUEL DOOR L FRONT FENDER LINER R FRONT FENDER LINER L REAR FENDER LINER R REAR FENDER LINER

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