VW/Audi Radiator Support Tool #3369 - Donuts
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Disclaimer: By reading this, the reader accepts full responsibility in performing the following work at his or her own risk. B5one cannot assume responsibility for any damage, injury, dismemberment or death, as a result of you the reader, following our instructions. We supply this information freely, for those interested in knowing what is involved with such modifications. If you find you would like to perform a similar modification to your vehicle, we urge you to first seek the advice of a qualified mechanic prior to undertaking any of the work. Some work will require physical strength that may be beyond your ability to perform.

DIY Rating:   Easy (1-1.5/5 Wrenches)
Time:   30 minutes
People Needed:   1

Parts Needed:

• Two (2) - 1/4 x 4" Steel or Brass Pipe (Obtained in the plumbing section of Lowe's or Home Depot.)
• Two (2) - M8 x 1.25 x 90mm hex head bolts (Can be tough to get. I use BoltDepot.com for most metric fasteners.)
• Two (2) - M8 Flat Washers (or an SAE equivalent—5/16" or 3/8")

Tools Needed:

• Hack saw or Dremel with cutting disks
• Bench vise or clamps
• Safety glasses or goggles

After recently renting the Blau Parts timing belt kit to do the timing belt on my B5 GLX, I was asked by Mike Egan to write up a "How To" on making a Rad Support tool (#3369) for our cars. It has taken a bit of time to actually do the write up but for the benefit of B5one here it goes.

The lock carrier tool from VW/Audi is little more than a piece of pipe with a bolt inserted through it which screws into a threaded hole in the front side members. The pipe then acts as a carrier on which you can slide the radiator support forward. Given that, making the lock carrier tools are pretty simple. It is just a matter of cutting pieces of threaded pipe to the proper length (80mm) and putting the bolt and washer through the pipe.

INSTRUCTIONS

1. Position threaded pipe in bench vise or use a clamp to bolt the pipe to a flat and study object like a railing or table. I opted for the steel pipe since it was only about $1.25 per length vs. $4.00 for the brass. Totally up to you!



2. Note: Always wear safety glasses/goggles when using cutting disks.
   Using the Dremel or hack saw, cut off one complete side of threads. Try to keep the cut as square as possible to assure the end will rest correctly against the side member when bolted on.



3. Measure remaining pipe to 80mm and cut off other side of threading. You'll have about 3mm of thread left but that won't matter since you can flip the pipe and that end won't be closest to the side member.
4. Repeat steps two and three for other 4" length of pipe.
5. Assemble your new lock carrier support tool. I didn't cut the wedge out of the pipe as shown in the top picture but the supports work perfectly fine.

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