Sadly, not a lot of progress yet, but I do have a few updates. At the start of this project, I discovered the headlight pods no longer work. A little troubleshooting with a MityVac revealed the vacuum system was sound except for the headlamp pod switch in the dash. Using this excellent post as a guide, the switch was rebuilt and now the pods rise and hold with vacuum.
Another discovery is that the poorly installed carpeting isn’t simply a function of carelessness when putting the pieces in place. Some of the visible gaps are due to incorrectly cut pieces. Therefore, repositioning to close one gap, simply creates a new one at the other end of the piece. Also, the carpet quality isn’t great, and the fraying at some of the cuts is prolific. Digging deeper, the sound deadening on the tunnel appears original, but the floors have much thinner, cheap looking padding.
With the seats out, and a better view of what I’m dealing with, I’m finalizing my recarpeting plan. Currently I am leaning towards using this German Wool Square Weave. It’s nice quality and appears pretty close to the original loop carpet used in the S4, although I suspect it might be a little thinner. Given that will aid installation under door seals, I’m okay with that.
As for underlayment, rather than go with the original felt, I’m considering using this 1/2" thick product from DEI: Under Carpet Lite™ Sound Absorption & Insulation - 70" x 72" (35 sq. ft.) - Design Engineering, Inc It’s a similar style but given the focus on sound and heat management using modern materials, it might be a bit more effective. Weight seems consistent with the original felt at < 0.25 lbs per sq. ft. My next step is to remove all the existing carpet and padding in preparation for the recarpeting and to run the new loom to the back of the car.
By any chance has anyone used the carpet CAD drawing for the S4 FHC located here? S4 FHC Carpet Set Cad Drawings If so, was it accurate? I’m hoping to have this printed to scale to use as a template for cutting the new carpet.
Thanks,
John