I sent 941 nuts/bolts/etc away for zincing and chroming, and I got 938 back, which I think is a very good efforting considering the minute size of some of them.
Before:
After:
The After pic really doesn't do them justice - they look so good in the flesh. For anyone doing some serious rebuilding work on their car - I would highly recommend getting the nuts and bolts cleaned up and re-zinced. They look a million times better, and the threads are so clean that it makes reassembly a breeze.
I spent a bit of time over the Christmas/New Years period ('06-'07!) bolting things back onto the car - custom seat mounts, pedal assembly/steering, custom dash mounts, rear suspension, headlights and headlight motor assemblies (which were stripped down, painted, powdercoated, etc), and various parts in the engine bay.
My S1 hubs have been machined down to fit the S4 discs, and I have had some custom caliper mounts made up for the S4 brake calipers. My struts are currently having some threaded sleeves welded onto them, so I'll take some pics of all these bits and pieces as soon as I get them back.
Also, the stud pattern has been converted to 4x114.3 on the new front brake setup, as well as the S2 rear end.
After a bit of hunting and a lot of patience, I was finally able to source the wheels that I have being trying to get for my Series 1. A massive thank you to Dom (Savannarx3) and also to John (autokiwi) for all your help (both via Ausortary.com).
The first thing I did when I got them home was test fit them on my Series 3:
They stick out of the guards very slightly on the Series 3, which matched perfectly with my measurements and calculations I made to ensure that I got the right offset:
Taking into consideration that the offset is +20 on a Series 1 (compared to +38/40 on a Series 3), they should fit almost perfectly, filling out the guards to the maximum. I'm a little concerned that the fronts are going to stick out a bit too far though, as my brake mods mean they will stick out a further 8mm from the standard hub.
All 4 wheels are 15x7, with a +11 offset. I really wanted to go wider on the back, but it appears that anything wider than 7" had offsets which were either too low, or negative. Bolting on some fugly flares is not an option with this car.
I have looked into having a pair of them widened, but it doesn't look feasible due to the way they have been manufactured (spun alloy).