To fit the Regula Tuning body kit to an Audi A4 B6 various modifications are required. Most of the modifications are very minor but the bonnet requires particular attention. All other modifications will also be mentioned below
Bruno Correia Audi A4 B6 8E Regula Tuning Body kit bonnet modification cut left

The Audi A4 B6 has an integrated grille on the bonnet so for the regula body kit to fit modifications need to be done to remove the front grille.

The first step is to mark the line using masking tape. You can either use the edge of the tape as a line or simply draw a line on the tape itself.

Do no remove the bonnet from the car and ensure that the front bumper bar is fitted to allow for easy alignment checking once the cuts are complete.

Prior to performing any cutting cover the entire car with a drop sheet (or similar) to prevent paint damage.Now using an angle grinder with a cutting disc carefully and slowly cut along the line.

With both cuts complete carefully lower the bonnet and check the cut and alignment against the front bumper bar.

If the alignment is good we can move on to covering the holes left by the removal of the grille mount. If the alignment needs to be adjusted repeat the above process by either cutting and/or grinding where required.

 Bruno Correia Audi A4 B6 8E Regula Tuning Body kit bonnet modification cut right
Bruno Correia Audi A4 B6 8E Regula Tuning Body kit incorrect install

The next step is important and is where we deviate from the standard install. The standard approach would be to simply cover the hole with a metal plate but the issue here is that it will result in an obvious gap between the bonnet and front bumper bar.

This is hard to explain so i will show a picture of a standard install.

Above is a picture of the standard install and it can be clearly seen where the original lip stops and where the hole was covered.

I personally was not happy with this outcome so instead a flat plate with a lip was welded in place to match the existing lip.

To the right is a picture of my install with no visible gaps.

 Bruno Correia Audi A4 B6 8E Regula Tuning Body kit correct install
Bruno Correia Audi A4 B6 8E Regula Tuning Body kit bonnet lip add-on

Using some cardboard cut out the profile of the hole. Once this has been done cut out the profile using 1-1.6mm plate.

dry fit the plate to the hole and mark where the original lip is. Now spot weld the lip on the plate (note: this is all done off the car)

The picture to the left shows both right and left side plates with lip spot welded.

Prior to welding the plate to the car ensure that it is completely covered using drop sheets.

Now spot weld in place and clean up with the grinder where required.

 Bruno Correia Audi A4 B6 8E Regula Tuning Body kit bonnet welded lip on left
Bruno Correia Audi A4 B6 8E Regula Tuning Body kit bonnet welded lip on right

Repeat the process for the other side.

Now slowly lower the bonnet into position. you will notice that the bonnet will no longer close as this additional lip has been added.

To resolve this a slight modification to the front bumper bar is required which is shown below.

The bonnet latch also needs to be modified so that the bonnet can open and close. The original bonnet latch is quite large and a type of "L" shape so that the bonnet can be opened through the Audi rings.

As the grille and audi badge are no longer part of the bonnet the "L" shaped portion of the lever simply needs to be cut off. If you find that the latch lever is difficult to grab on to, you can put a slight bend in the lever.

Note: Don't bend the leave too much as it may hit your radiator when the bonnet is closed.

 Bruno Correia Audi A4 B6 8E Regula Tuning Body kit bonnet latch mod

Using a multi tool cut out a small notch the length of the lip that was added to the welded plate.

The will allow for the fabricated lip to neatly sit behind the bumper bar when the bonnet is closed.

 Bruno Correia Audi A4 B6 8E Regula Tuning Body kit modified front bumper bar
Bruno Correia Audi A4 B6 8E Regula Tuning Body kit modified front bumper bar

Repeat the process for the other side.

Once the notches are complete and the bonnet closes neatly without touching the bumper bar, its time to clean up the bonnet using body filler and prep for paint.

Below are a series of pictures showing the clean up and shaping process using body filler.

 Bruno Correia Audi A4 B6 8E Regula Tuning Body kit clean up bonnet with body filler
Bruno Correia Audi A4 B6 8E Regula Tuning Body kit clean up bonnet with body filler
Bruno Correia Audi A4 B6 8E Regula Tuning Body kit clean up bonnet with body filler
Bruno Correia Audi A4 B6 8E Regula Tuning Body kit clean up bonnet with body filler

Once we were happy with the prep the bonnet is sent off for paint.

The final finish

 Bruno Correia Audi A4 B6 8E Regula Tuning Body kit finished painted bonnet
Bruno Correia Audi A4 B6 8E Regula Tuning Body kit finished painted bonnet
Bruno Correia Audi A4 B6 8E Regula Tuning Body kit finished painted bonnet
Bruno Correia Audi A4 B6 8E Regula Tuning Body kit finished painted bonnet

 

The front bumper bar includes all the factory mounts and also includes two additional mounts.

This modification is required to secure the bumper bar using the additional mounts

 Bruno Correia Audi A4 B6 8E Regula Tuning Body kit front bumper non standard mounts
Bruno Correia Audi A4 B6 8E Regula Tuning Body kit front bumper non standard mount holes

When dry fitting the front bumper bar mark the centre of the additional mount on the front fender for both the left and right.

Transfer the mark to the bottom of the fender and drill a hole. This can be seen in the picture on the left.

The next modification will allow you to align the bonnet to front bumper bar gap with ease.

It involves adding an aluminum adjustment plate to the standard crash bar (removed from the original bumper)

The aluminum plate is approximately 10mm thick and has a slot for easy adjustment. The bolt holding the adjustment plate is threaded directly into the crash bar.

 Bruno Correia Audi A4 B6 8E Regula Tuning Body kit front adjustment plates on the crash bar
Bruno Correia Audi A4 B6 8E Regula Tuning Body kit front adjustment plates on the crash bar

Now with the bonnet closed the front bumper bar can be easily adjusted using the aluminum plates. This adjustment process will occur using the dry fit phase and will occur when the mesh is not installed to allow for easy access.

Once complete, paint in matte black as these adjustment plates will sit behind the mesh.

For the rear bumper to sit flush with the existing panel there are 2 or 3 small tabs on the plastic mount that needs to be removed.

Use a flat head screw driver and tap with a hammer. The tabs will fall right out.

Now the rear will sit flush.

 Bruno Correia Audi A4 B6 8E Regula Tuning Body kit rear bumper bar mount modification