I’ve been working on the serpentine belt routing so I can hook up the alternator. I cut down one of the original engine brackets and relocated the idler pulley. The new pulley location should allow me to install a serpentine belt for just the alternator while utilizing the original belt tensioner.

I ordered a new 250 amp high output alternator but it turns out that Audi used two alternator styles in the early 2000’s (Bosch style and Valeo style) and the HO alternator uses the larger Bosch style housing that won’t clear the frame. I was able to get a 120 amp alternator in the Valeo style that should fit. The electric steering pump draws up to 70 amps in some (very rare) conditions but only 10-20 amps during most driving so I’m hoping the 120 amp alternator will be sufficient. It’s the highest output I could find in the Valeo style unit.

The original outside door handles are in bad condition and one is cracked. Replacements are not available so I’m switching to solenoid door poppers. I was going to use a round escutcheon plate for the opener button but I think rectangular looks better and matches some of the other exterior components. I’ll paint the rectangular plates black.

I’m using original door latches but I was able to find new OEM replacements for the door strikers. Mine are both worn. I’m using the original interior door handles but replacing the clumsy rod arrangement with a simpler pull cable.

I installed Vitaloni door mirrors and LED headlights. I have silver and black trim parts for the headlights so I may switch to silver if it looks more period correct. I finished hooking up the parking brake. I mounted the hood to the hinges but I’d rather have the hood forward-opening so I’m still looking for other hinges.

Besides the items in progress, I have several items that I want to complete before I take the car on the street. The car is registered as a collector vehicle but I’d rather not have too much scrutiny because a lot of items have been replaced. Todo: grills, windows, some exterior lighting, some additional chassis wiring. I’ll want to replace the very old tires before I do much street driving.