Quattro Rally Build Axles and Headlight Bezels

In our last update you may recall that we installed the exhaust manifold, wastegate and turbo, made the crank position and speed sensors fit and installed the flywheel and clutch. This time we’d like to be going over getting the engine but, alas, we need some parts before we can do that. So we turned to our backup list and rebuilt the axles as they are needed to move the car should we ever get it running. Of course, we may get distracted along the way by something fun.

We were hoping not to have to rebuild our axles as they seemed sound and intact. However, upon closer inspection:

A close-up view of a damaged automotive CV joint boot, showing rust and a crack in the rubber boot. The background includes a work surface with tools and a canister.

So we guess we’re goin in. Fortunately we had some boots stored in our parts stash.

Box of an Audi axle boot repair kit with part number 431 498 203D, labeled '1 PIECE' and marked 'MADE IN GERMANY'.
Close-up of a box labeled 'Axle Boot Repair Kit' by Audi, showing the part number 443 498 201, with a patterned background featuring the Audi logo.

Unfortunately not enough for all four axles so we went on the hunt. These are getting really rare now but we managed to cobble a full set together from around the globe. Rebuilding axles is a messy job but, upon inspection ours proved to be in good condition, only needing new grease and boots.

A close-up of a grease-covered automotive part being held in a vice, with a work surface visible below.
A close-up view of a disassembled mechanical component on a workbench, featuring a metal shaft and a disassembled part in an orange container with grease.
An assortment of mechanical parts including a drive shaft, ball bearings, and a tube of grease on a work surface covered with patterned paper.

Good as new!

A car axle with rubber boots resting on a concrete surface.

With the messy chore out of the way and no parts on the horizon we looked for something fun to do. We like shiny objects so decided to refurbish our headlight bezels, ironically by making  them less shiny! According to the pictures we found online the rally bezels had a lot less chrome on them than the standard bezels (as well as being half the size of course) We knew what we had to do: get the masking tape and  satin black rattle can out! Details matter.

Close-up of a vehicle headlight assembly, featuring a clear lens and an amber turn signal light, mounted on a black trim, with an orange panel above it.
Close-up of a rectangular frame with an orange light section, resting on a textured surface.
A black plastic automotive part hanging by a wire in a workshop setting.
A clear plastic car light housing with an amber lens on one side, placed on a table.

and we’re going to need a new lens for the reflector too.

A person's hand holding two orange reflector lens covers, one with a textured surface and the other smooth, with a metallic frame partially visible.

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