Welcome to the Audi A6 Widebody Project — a bold, hands-on transformation turning a stock A6 into a head-turning custom build. In this first video of the series, builder Sam Kimmel walks us through the early stages of the project, sharing behind-the-scenes footage and techniques used to prepare the platform for a full widebody conversion. If you’re into DIY automotive fabrication, widebody installs, or custom metalwork, this build is for you.

Getting Everyone Up to Speed

Before diving into the current state of the build, Sam rewinds the clock with raw clips of the initial teardown and body prep. From clearancing the wheel wells to reshaping the fenders, this catch-up video is essential context for new followers of the project.

Without showing where the car started, it wouldn’t make sense for people just now jumping in.

Sam Kimmel

The video includes early footage of:

• Cutting and trimming the wheel wells with an air nibbler and die grinder
• Massaging the inner fender lip using tubing and a tire for leverage
• Pulling the wheels and test-fitting wide tires to dial in fitment

These steps laid the groundwork for fitting massive 335/25/20 tires and achieving the aggressive stance the build is now known for.

Fabrication Techniques and Tools

Sam shares valuable insights for any fabricator:

• Air nibblers make clean cuts but leave tiny metal shards—watch your shoes.
• Die grinders help reach tight corners and finish cuts.
• Bodyman’s hammers and leverage tricks allow for fender reshaping without expensive tools.
• Using everyday materials like packing foam to create mirrored fender templates on both sides.

He also gives safety tips, such as wearing protective gear—even if he admits skipping the die grinder guard during filming.

Building Around Air Suspension

The Audi rides on Airlift V2 suspension, and while installation footage wasn’t captured early on, you’ll see the system in action as Sam raises and lowers the car to fine-tune tire clearance. Small adjustments to metal near the rocker panel and firewall ensure no rubbing during full steering articulation.

In the video, Sam:

• Clears the front inner fenders for tire turn clearance
• Grinds back undercoated rocker panels
• Tests turning radius post-clearance

The effort pays off with a successful first drive, proving the car rides and handles well with the new wheels and clearances.

Additional Mods and Shop Move

This widebody build isn’t just about fender flares. Sam reveals:

• A modified stock front bumper, extended by 2 inches for a more aggressive front lip
• A custom exhaust, handcrafted from pie-cut tubing before he had access to a tube bender

After relocating to a new shop, Sam continues refining the fenders, using DIY templates and repeatable cut methods to ensure symmetry on both sides. He even relocates a vacuum line to keep the bay clean for future fabrication.

What’s Next in the Audi Widebody Build?

This video is a foundation — future episodes will dive deeper into:

• How to create widebody flares from fiberglass or carbon fiber
• Full bumper fabrication
• Exhaust tuning and interior details
• Answering viewer-submitted questions and how-to requests

If you’re curious about body panel clearance, or want to see how a high-performance widebody build comes together piece by piece, make sure to subscribe.

Final Thoughts

The Audi A6 Widebody Project is more than just a visual upgrade — it’s a testbed for creativity, fabrication skill, and grassroots engineering. This first video is your chance to get caught up before things get even wilder.

💬 Have questions about custom fenders, air suspension, or building widebody kits from scratch? Drop them in the comments — future videos will answer them directly.

📺 Watch the full build video on YouTube

👍 Like what you see? Hit the like button, share it with your fellow gearheads, and subscribe for the next chapter in this widebody evolution.