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Morninglight
20-07-2005, 04:20 PM
My '85 1600D caddy:

What is already done:
Refurbished starter
Refurbished Bosch 65A alternator
Replace wiring from and to battery with >alternator=10mm² and + starter 25mm² and - 2x 25mm² (in advance to my audioproject)
Optima Yellowtop battery
K&N airfilter (is the same as a Mk2 GTI 16v PL engine)
22.2mm masterbrakecylinder with GTI 16v Booster
Ventilated 256mm discs with 54mm calipers in front
Rear discs (scirocco mounts with A3 calipers)
Replaced all wheelbearings
Lowered rear ~200mm front ~50mm
Rear exit exhaust
Corrado half-leatherseats
Borbet A 7.5x16 & 9x16 with black spokes and flat hubcovers
Tyres: 195/40R16 & 215/35R16 Dunlop SP Sport 9000
ATS Cup winterwheels (black with 195/50R15)
Power windows (From an Alfa Romeo 33)
Hood lifts
Camco alarmsystem w/ remote start


Things to do: (I've got most parts waiting in my toolshed)

JR TD 70HP engine
Intercooler
Tuning the JR
RA (80hp) pump + injectors
60mm DP & exhaust
Cabrio dash (soft instead of the plastique)
Cable shifted TD tranny
Water leaking windscreen
Height adjustable schocks IN FRONT
Further lowering the rear
Moving the battery to the rear with a 2nd yellowtop
Front bumper removal, blinkers in the bumper support holes
Paint (black)


How my caddy looks now:

http://www.morninglight.nl/a3/caddyc1.jpg
http://www.morninglight.nl/a3/caddyc2.jpg
http://www.morninglight.nl/a3/caddyc3.jpg

I mounted the ugly bumper for the inspection, this is how my front will look in a few weeks (Single light grill and without the ducttape with round blinkers ;))

http://morninglight.demon.nl/a3/vspoiler1.jpg

Engine bay

http://www.morninglight.nl/a3/caddyc5.jpg

My ride when the caddy is under sugery:

http://www.morninglight.nl/a3/caddyc4.jpg

;)

2ltCADDYSPORT
20-07-2005, 06:10 PM
cool truck,love the rims!!!!

P4ulo
20-07-2005, 10:43 PM
I love seeing a project at the beginning.

What plans are afoot my friend, colour and what trim?

Nice, Paulo.

P4ulo
20-07-2005, 10:44 PM
Sorry, I saw your plans.
Black is cool.

veedubjoe
21-07-2005, 06:36 AM
I wish I had kept my Borbet's now! Sweet Ride!

Morninglight
21-07-2005, 07:44 AM
I love seeing a project at the beginning.



I bought the truck about a year ago, what I wrote down is about half the time I already spend on it... a LOT of rust }:)


I wish I had kept my Borbet's now! Sweet Ride!

I love them too.. Borbet A (7.5x16 all round) were the first set of wheels I bought for my first car, a Scirocco 16v when I just got my driverslicense at 18 years and a few months :D

2nd reason is that about 30% of the styled Vw's overhere have BBS RM001's, 20% Porsche C2, 10% Porsche Telfon and the rest has ATS cup 15" or ATS Classic 13"... NOT very original.

And about the color, it will not be shiny black but ... black (whats 'not shiny' it called in english?) just like the spokes of the borbets.

Jimmy
21-07-2005, 08:31 AM
nice to see another dutch caddy fan on the forum :) as for the paint - if its not gloss (shiny) black then it can be satin (kinda shiny but not) or matt black (not at all shiny - rat style) :thumbs_up

borbet A's are just hard as fcuk - no messin' :music:

Morninglight
21-07-2005, 08:39 AM
Rat style it is then ;)

m6m62
21-07-2005, 10:13 AM
The Alfa electric windows sound interesting. Did you use the full lifter mechanisms from the Alfa ? I know there are other ways of doing this (as detailed by Al in an earlier post), but sounds like this could be another option.
Cheers,
Mark

Morninglight
21-07-2005, 10:39 AM
Check the How-To section :)

Darth Garry
21-07-2005, 11:59 AM
Yo, that's awesome bro! Especially sticking with the diesel! I don't know if you've ever driven a turbo diesel but it's a world apart from the n/a! It appears that your rear exit exhaust is sooting up the back pretty bad though. I stuck with the side exit on the truckdoza as it reduces sootiness on the paint, and backdraft into the cab.

Can't wait to see the progress!

GArry

Morninglight
21-07-2005, 12:28 PM
Yo, that's awesome bro! Especially sticking with the diesel! I don't know if you've ever driven a turbo diesel but it's a world apart from the n/a! It appears that your rear exit exhaust is sooting up the back pretty bad though. I stuck with the side exit on the truckdoza as it reduces sootiness on the paint, and backdraft into the cab.

Can't wait to see the progress!

GArry


My Audi A3 is powered by a 1.9 TDI, so I know what a diesel can do :p

The back is more smudgy than usual cause I refuel with 50% diesel and 50% vegetableoil but that color difference will fade away when I paint the car ;)

Darth Garry
21-07-2005, 04:24 PM
Half veggie oil? That's awesome!

Garry

Morninglight
21-07-2005, 05:25 PM
Half veggie oil? That's awesome!

Garry

Mr Diesel designed the Diesel enging at a time when gas was very, very expensive.. so he created an engine that could run on all kinds of oily stuffs :)

The veggieoil I use is sunflower oil which you can buy at the price-discountmarket for €0,59.. compare that to the dieselprice of ~€1,05 per liter. So I save 25x €0,56 per full tank :)

I know some dudes who use 100% oil from the local snackbar, but then you must install a 2 tank system and preheating before the dieselpump will swallow it. I'm slowly gathering the parts for a similar setup, I don't drive enough with the caddy to buy a complete setup at once considering cost efficiency.. but a frenchfriessmell coming from your exhaust is a nice showoff ;)

I just picked up a GTD cockpit with revcounter.. I'm going to mod that with a 260km/h speedo from a 16v and I'm scanning the clockplates as we speak for a nice custom look :)

Morninglight
29-07-2005, 07:32 AM
I just got a great offer on a 1.9TD AAZ engine complete with turbo and stock intercooler... the 300cc extra over the 1.6TD (I can sell it anytime for €350,- ) that I'm cleaning in my toolshed is tempting but I'm not sure if it will be a good idea though.

Morninglight
29-07-2005, 10:17 PM
I got sick from my front shocks... The scirocco 16v shocks I used were to weak and didn't leave any room for wheeltravel when it was as low as on the pics above }:)

So I shoved out some cash and bought me an nice set of heightadjustables 8D -20 to -100mm range :music:

http://morninglight.demon.nl/a3/schroef1.jpg
http://morninglight.demon.nl/a3/schroef2.jpg

I lowered it to about 2/3rd of the complete thread down :)

Morninglight
30-07-2005, 05:17 PM
Front was totally off wack.. but check the rear (achter), I mounted the rearaxle and aligned it on eyesight.. sporing and rijhoek=driving angle, those 2 tell how straight the rear axle sits behind the front :D

http://morninglight.demon.nl/a3/schroef4.jpg

http://morninglight.demon.nl/a3/schroef3.jpg

This is low enough to be drivable overhere with all the speedbumps :)

And I swapped the 1.6TD that I was geting ready to be dropped into the caddy for a 1.9TD AAZ:

http://morninglight.demon.nl/a3/aaz1.jpg

:p

veedubjoe
30-07-2005, 06:21 PM
I have the same 1.9TD AAZ engine to pur into mu Caddy. It's literally just been fully rebuilt, so once I've moved house later this month I'm gonna get on and put it in. I've got the intercooler but I haven't got the correct mounting for it from a mk2, which I need to get.
Apparently the 1.9TD AAZ engine in a Caddy goes like stink.

Morninglight
30-07-2005, 06:37 PM
Apparently the 1.9TD AAZ engine in a Caddy goes like stink.

ROFL :D :D

I'm going to swap the LDA pin for the agressive LDA I've got in my 1.6 GTD pump, the it is going to stink even more :music:

Can you confirm that the injectors in the AAZ are dnosd 308? When the AAZ injectors are compatible and smaller I'll drop the 1.6GTD dnosd 274..

I'm not going to use the GTD thats on the picture, I've got a big 90x29x4cm front mount IC.. much easier to fit in the small enginebay :)

Do you have any point to look at before dropping the engine in? I've heard that a enginemount from a certain gas Mk1 is needed?

veedubjoe
30-07-2005, 08:55 PM
well i've already got the 1.6TD in mine, but the injector pump was knackered so it only has the n/a 1.6 inector pump at the moment, so its a bit down on power. So as for engine mounts mine already has the correct one for the 5 speed box, although I don't know what its from as I bought the caddy with the 1.6TD already in it.
But I'm also putting the 5 speed from the 1.9TD in the Caddy too. I'm not sure what the spec of the injectors are to be honest. I bought a whole mk3 1.9TD with a cracked head for £40 off my girlfirends dad, and I managed to pick up a recon head, pump and turbo for £25 from Ebay!! The car also had a new radiator on it already so I'm gonna use that with the twin fan set up.
I'm also gonna buy a big front mount intercooler. But that will have to wait until I have a few spare pennies.
I run my Caddy on 50% vegetable oil. My Dad runs a twin take system on his Mitsubishi L200 and he can do the full installations, so once I've had my Caddy sprayed and had the tonneau cover made for the back I'm gonna fit a nice big alloy fuel cell behind the Cab and run the twin tank setup. So many more miles of half price motoring. I love the smell of it and it makes me laugh when you sit in traffic and you can see everyone trying to work out where the smell is coming from!
I've also been told that running a T3 turbo works wonders for that engine too, and with an intercooler you'd be looking at 120bhp and a mass of torque!
Be really interested to see how you get on, I'll keep you updated on my progress with the install.

Morninglight
31-07-2005, 03:54 PM
I've did some research:

http://morninglight.demon.nl/a3/steun.jpg

The enginemount 6 is the one that is orignally on a 1.6(T)D, the one marked with 5 is the one you need to mount the 1.9TD in a MK1. Partnr. 055 199 293 G Costs €22,- at the dealer (you also need the other parts 1, 2, 3 and 4)

Morninglight
05-08-2005, 07:39 AM
The donorcar:

http://www.morninglight.nl/a3/19td10.jpg

1.9TD AAZ '97

http://www.morninglight.nl/a3/19td9.jpg


http://www.morninglight.nl/a3/19td8.jpg

Enginemount from a type 1 gasser:

http://www.morninglight.nl/a3/19td7.jpg

New belt and tensioner

http://www.morninglight.nl/a3/19td6.jpg

Had some fun with a Passat bumper... :screwy:

http://www.morninglight.nl/a3/19td5.jpg

http://www.morninglight.nl/a3/19td4.jpg

trusty old 1600D has got to go

http://www.morninglight.nl/a3/19td3.jpg

http://www.morninglight.nl/a3/19td2.jpg

http://www.morninglight.nl/a3/19td1.jpg

The TD was in the caddy at about 21.00h (did some parting out the golf) but I think I have a little problem with the diesel... it runs after a long start but doesn't idle when I give it a LOT of diesel with the screw on the side of the pump.. when I set it back to orignal is just vrrrrrmms... once in a while, going to have a look later today :)

Morninglight
06-08-2005, 10:27 PM
I forgot one pic... :rolleyes:

http://morninglight.demon.nl/a3/19td8.jpg

Ok.. most of the problems are solved, I didn't have time to properly time the pump but it runs ok for now and I can shift thru all gears (was planning a overhaul soon).. no smoke and quick response to the throttle 8D



veedubjoe
Apparently the 1.9TD AAZ engine in a Caddy goes like stink.

the AAZ is still stock (maybe a bit more fuel) but I think I already fooked my right axle... it really goes like stink :music:

http://morninglight.demon.nl/a3/turbodrukm.jpg

It only goes to about 0.75bar.. but not for long :p

Caddy-Daddy
07-08-2005, 06:00 AM
Ok.. most of the problems are solved, I didn't have time to properly time the pump but it runs ok for now and I can shift thru all gears

Hahaha I told you it was a timing problem :D :D :D .

If you wanna run more boost than 1Bar (14.7Psi) constantly than it is advisable to swap the AAZ KKK-K14/Garret T2 Turbo with the one from the 1.6TD either KKK-K24/Garret T3.
They take longer to spool up but 2 Bar!!!(28Psi) is achievable..By then you will be looking at 300-400Nm of torque.
So a TDI gearbox will be needed to cope with this amount of power. TDI Trannys can cope with 500Nm Torque.

I'm running 1.2 Bar on my 1.6TD and is already fast as F .... and yess I'm one of the before mentioned "Dudes" that run a 100% Veggie Powered twin-tank set up !! :8 :8

Morninglight
07-08-2005, 07:26 AM
Al lot of things need fine-tuning, so thats on the program for the coming week, after that: intercooler.. I'm nog going to use the T3/K24 I think, I don't like the turbo lag. (still remember when we raced? I kept up with you till 3rd with my 1.6D)

The rattle on the right side was not the axle... it was the coilover that was not properly tightened, just like on the left side the wheelalignment dude "forgot" it :screwy: :screwy:

Off to VWmania then :D

Caddy-Daddy
07-08-2005, 08:11 AM
still remember when we raced? I kept up with you till 3rd with my 1.6D

True.. But that's only because I still have the Bog standard Toiletbowl Downpipe that restricts flow from 55mm at Turboside to 45mm exhaustside. Also my fueling is still in the let's save the environment from polution mode.

So spooling takes forever..with a Big Ass Turbo like the T3. But when she kicks in it's like driving on NOS. Well French Fries NOS in my case. ;) ;) ;)

So with a 2.5" or 3" DP and optimum fueling the T3 or K24 still is the better option.

Morninglight
07-08-2005, 08:26 AM
I'm not going the easy way and swapping the T2 for a T3... maybe a GT15/20 :p

I have a 02A tranny from a passat 1.9D, how much torque can it handle?

veedubjoe
07-08-2005, 08:45 AM
Wicked! I have a 1.6td in mine at the moment so all I need to do is bolt the turbo from that onto my AAZ when I drop it in later in the month?!

That solves the problem of changing the downpipe then because the flange is different on the turbo from the AAZ.

Caddy-Daddy
07-08-2005, 08:56 AM
The Ballbearings and the watercooling of the GT15/20 will help keeping things in balance and cooling up but for higher as 1Bar Boost best is to choose a bigger version of the GT series.

I'm not sure how much torque the 1.9D Passat Tranny can cope with, but I think it would be in the same range as the 1.6D/TD Tranny.

The 1Y 1.9D engine max Torque is: 124Nm/2000 Rpm.
The AAZ 1.9TD engine max torque: 150Nm/2400 Rpm
JR / MF 1.6TD engine max torque: 133Nm/2600 Rpm
RA/SB 1.6TD GTD engine max torque:155Nm/ 2500 Rpm.

So it will definately take less torque than the TDI tranny.
TDI specs are i.e. AFN(110BHP): 235Nm/1900 Rpm

Caddy-Daddy
07-08-2005, 09:02 AM
@ Veedub Joe: The AAZ Turbo DP is already 2.5" So if you could use this on the K24/T3.. then you're in freeflow mode already. :thumbs_up

veedubjoe
07-08-2005, 09:56 AM
spot on! cheers buddy! now i have all the info I need to know! I reckon the Caddy's gonna be quicker than expected! Would be lovely if it outpaced my mates mk3 8v GTi, not very hard though!
Should make motorway journeys to No-rice meets more interesting anyway!
Your technical knowledge is outstanding, thanks Caddy Daddy!

JuniorMcNasty
07-08-2005, 05:28 PM
Beautiful project you have going . Keep us posted :thumbs_up

Caddy-Daddy
09-08-2005, 10:33 AM
Would be lovely if it outpaced my mates mk3 8v GTi, not very hard though!

That's a piece of cake.. :D :D

He will have more top end but at the trafficlights and in the first 3/4 gears you will be much quicker.

Morninglight
11-08-2005, 05:30 PM
My 1.9TD is coming together... at last 8D

http://www.morninglight.nl/a3/bay1.jpg

I installed a open-air filter (bought cheap at VWmania) and my radiatorthingy (dunno in english), the rest of the blingparts are planned this weekend :)

I ordered the special tools to properly time my injectionpump but the bastards forgot to order some parts and when the parts wery finally there one part was not ok.. so I hope I can time my pump tomorrow.. but it already flies compared to my 1.6D :music:

And my downpipe is finished:

http://www.morninglight.nl/a3/downpipe1.jpg

70mm/2.75" :D

Mr Brick-Yard
18-09-2005, 08:38 PM
Look at the size of that!
Just been offered a 1.6TD Passat motor for not very much, done star ship miles but it's cheap.
Quick rebuild and I'll be dropping it in.
It's nice having to learn about things again, used to T3 stuff and it's quite tedious.
So, 1.6TD will use the original 1.6D mounts? have I read this right?
Then it's home brew the downpipe?
What clutches does everyone use?
Not really looked into this much, s'pose a flick through a clutch book wouldn't go amiss!
Is it a GTi clutch or are they all the same?

Morninglight
18-09-2005, 09:23 PM
The downpipe is homemade by a good friend (can be ordered for €165,- ex shipping ;)) I'm still using the stock clutch &tranny from a Mk2 golf 2 GTD but I don't think it will last long, when it starts to fail I think I swap it for a 02A cableshift tranny from a TDI with a sachs sportclutch.

All the mounts from the 1.6D need to be swapped to the TD, if the dstributionside is different in the passat the mount that supports the injectionpump needs to be swapped too.

My project is continued in the topic:

http://vwcaddyforum.com/showthread.php?p=45830#post45830

I'm upsizing some other stuff too :D

punkvideo81
05-10-2005, 10:25 PM
It's great to see others working on TDI swaps in a caddy. I would really like to to this someday. In the meantime, I have the veggie oil thing covered already on my 1.6 diesel n/a. I have a 2 tank setup like Morninglight was talking about. I got a kit from greasecar.com and installed it over the weekend. I already did one of these a year ago on a 1986 VW Golf Diesel (non turbo) and it worked great. Will post pictures of the whole system soon. Would like to have the power of a TDI with the free veggie oil as a killer low operating cost/high performance utilitarian vehicle combo!

Morninglight
06-10-2005, 07:30 AM
It's great to see others working on TDI swaps in a caddy.

The engine is not a TDI, it's a TD AAZ engine from a MK3 golf/rabbit. Mechanical injected 1900cc IDI engine,

punkvideo81
07-10-2005, 02:34 PM
I didn't know there were IDI 1.9's. I think here in the USA if you have a 1.9 it's usually a TDI, but I suppose you can never say never. I found a local junkyard that has a 2000 TDI engine plus 5 spd tranny for $3150...Any opinions on the price?

Morninglight
07-10-2005, 04:12 PM
I think the price is a bit steep, but if everything is included like cluster/keys and stuff you need for the swap and it has very low mileage and warranty it is ok.

punkvideo81
07-10-2005, 05:12 PM
i don't know about the cluster/keys (didn't know I needed them, but will ask) but it supposedly has 70k miles on it, and i doubt it has a warranty. what else do i want to grab to make it an easy swap? thanks.

Morninglight
07-10-2005, 06:28 PM
The ECU won't give the engine free to start when the key is not in the lock, the cluster communicates with the ECU.. So you need both, or modify the ECU or run a mechanical pump.

The easiest swaps are the 1.6 and 1.9TD, but since you don't have a lot of 1.9TDs around it can be more expensive (I got mine for $200 incl gearbox, alternator, steeringpump, intercooler etc).

Iowa Caddy
07-10-2005, 08:15 PM
...what else do i [need] to make it an easy swap?A coupla' thousand $$ more. :D :D And a coupla' years of spare time (or multi weeks full-time). http://vwcaddyforum.com/showthread.php?t=5286

Not trying to be negative or to talk you out of it -- just giving ya' a heads-up on the complexity of the swap. Keeps us up to date on your progress.

I didn't know there were IDI 1.9's. I think here in the USA if you have a 1.9 it's usually a TDI...We didn't get 1.9's, but Canada did. You may be able to find one that came across the border. Or slip up to the GWN and get one. Or try Parts Place Inc. -- they used to advertise that they had a bunch of 1.9 TD long-blocks. Much easier swap than a TDI.

punkvideo81
13-10-2005, 08:57 PM
Hey Iowa Caddy and MorningLight,
I tried the Parts Place for the 1.9TD (thanks, they are great guys) but apparently they are all out of them. I did find the AAZ engine code 1.9 TD at zsimports (in Nevada, USA) as well as the 1.9 TDI and either one is $3495.00...what do you think, guys? http://www.zsimports.com/Mechanical/index.htm

Morninglight
13-10-2005, 09:13 PM
If you can get them for the same price I would go for the TDI...