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Thread: 2.0 8V MK1 Caddy Quick build (hopefully)

  1. #41
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    Nov 2007
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    Tremendous effort and thread so far - you are doing a great job.

    You know that you can pull the filter out of the middle of the fuel tank if your tank is full of crap.

    Keep up the progress!

    Where do you want to race? Drag? Hill climbs?

  2. #42
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    Jan 2011
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    Thanks 13!

    What is this filter you speak of, is it the circular thing in the middle? i finished electrolysis on the tank today and its filled with crap yup, i was thinking steaming it?

    hill climbs would be cool, was just thinking of track days, but that wouldn't be for a while till i got comfortable with the car, fastest car i've driven is a 75hp lupo followed by a 60hp up

  3. #43
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    Quote Originally Posted by Nick-Nack View Post
    fastest car i've driven is a 75hp lupo followed by a 60hp up
    I am quite sure my 75hp Up! is the slowest car on earth

    I thought i had some pics.... let me look.

  4. #44
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    almost finished the sill and rear turret, got a small bit of sill to finish and put the turret on, but here's what ive done in the last 3 days.

    Repo sills are very frustrating, especially when they're shaped like a banana.

    Fixing a previous patchwork...

    rear arch.jpg
    rear arch 2.jpg
    rear arch 3.jpg

    Seam sealing under the turret panel and welding it in

    rear sill turret.jpg
    rear sill turret 3.jpg
    rear sill turret 4.jpg

    Finishing off some bits before putting sill on

    sill.jpg
    sill 2.jpg
    sill 3.jpg
    sill 4.jpg
    sill 5.jpg
    sill 6.jpg
    sill 7.jpg
    sill 8.jpg

    This took a while...

    sill install 1.jpg
    sill install 2.jpg
    sill install 3.jpg
    sill install 4.jpg
    sill install 5.jpg
    sill install 6.jpg
    sill install 7.jpg
    sill install 8.jpg
    sill install 9.jpg
    sill install 10.jpg
    sill install 11.jpg

    Still having grinding to do, but its on there, its not perfect, but its pretty difficult to get it perfect as it's a repo to start with.

  5. #45
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    Nov 2010
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    You're doing a fantastic job with the welding and fabrication work. Its in a similar state to how mine was. I did all the work to mine myself and it was the first project i had ever done so reading this thread takes me back to the pain I endured fixing up mine. Keep at it and it will be well worth all the effort in the end.

  6. #46
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    thanks a lot andy, i did read your thread with all the rear end and sill work, that's where i got the confidence from, so thank you for that i wish i could say i did it all on my own, but i had help from a friend for most of the front end work, so i can really understand all the hard work you did as it was tough enough with 2 of us!

  7. #47
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    turret and end piece of sill done today! 90% complete, just grinding welds back and painting then it's done!

    turret 1.jpg
    turret 2.jpg
    turret 3.jpg
    turret 4.jpg

    accidentally grounded down the turret while removing the seized in bolt a while ago, so sandwiched 2, 2mm plates together as a replacement

    turret 5.jpg
    turret 6.jpg
    turret 7.jpg

    Welding in a back piece behind the turret to stop crap getting in behind it
    turret 8.jpg
    turret 9.jpg

    welding it back in after careful measurement, also put in 1mm thick strips along side it so i'm not just welding to the panel directly.
    Cranked up the welder, welding thick metal is so much easier than thin metal..

    turret 10.jpg
    turret 11.jpg

    Attached the end piece of the new sill to my old sill, slightly different so had to bend them to fit eachother, but got there in the end.
    also attached a strip at the end of the inner sill to the inner rear arch, should add a lot of strength.

    inner sill 1.jpg
    inner sill 2.jpg

    Trick i learnt, put new metal ontop of old that you're replacing then cut both same time to get perfect 1mm gap.

    sill install pt2 1.jpg
    sill install pt2 2.jpg

    Went very slowly welding it in, didn't want to warp panel, so dabbed damp rag after every couple welds.

    sill install pt2 3.jpg
    sill install pt2 4.jpg
    sill install pt2 5.jpg
    sill install pt2 6.jpg
    sill install pt2 7.jpg

    All i have left to do is grind the welds back then paint it! rinse and repeat on other side.

    it's not perfect, i'll have to use body filler, but it's strong, which is what matters the most, and rust free!

    Tomorrow and tuesday i should be able to get a lot of work done on the other side.

  8. #48
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    Quote Originally Posted by Nick-Nack View Post
    thanks a lot andy, i did read your thread with all the rear end and sill work, that's where i got the confidence from, so thank you for that i wish i could say i did it all on my own, but i had help from a friend for most of the front end work, so i can really understand all the hard work you did as it was tough enough with 2 of us!
    I'm pleased that my build thread has helped people out, it makes it worth all the time and effort writing it up if people are reading it and learning something from it. I really need to get it up to date now all my photos have returned since photo bucket have done a u turn on the third party hosting ban. Keep up the good work on yours, I do like to check in regularly to see how its coming along.

  9. #49
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    Jan 2011
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    sills and turret all done! Accidently cut the wrong side of my brand new turret sill... so had to weld it back on
    Also put some plates in the chassis rail next to the turret to add some strength.

    Enjoy 28 pictures.

    sills pt2 1.jpg
    sills pt2 2.jpg
    sills pt2 3.jpg
    sills pt2 4.jpg
    sills pt2 5.jpg
    sills pt2 6.jpg
    sills pt2 7.jpg
    sills pt2 8.jpg
    sills pt2 9.jpg
    sills pt2 10.jpg
    sills pt2 11.jpg
    sills pt2 12.jpg
    sills pt2 13.jpg
    sills pt2 14.jpg
    sills pt2 15.jpg
    sills pt2 16.jpg
    sills pt2 17.jpg
    sills pt2 18.jpg
    sills pt2 19.jpg
    sills pt2 20.jpg
    sills pt2 21.jpg
    sills pt2 22.jpg
    sills pt2 23.jpg
    sills pt2 24.jpg
    sills pt2 25.jpg
    sills pt2 26.jpg
    sills pt2 27.jpg
    sills pt2 28.jpg

    I have the inner rear arches to do, rear valance, tidy up the cross members and do the rear leaf springs, getting close!

  10. #50
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    Jun 2013
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    kent
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    awesome work! where did you get your rollover jig?

  11. #51
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    South Wales
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    Thanks buddy! got it from here https://www.rolloverjigs.com/product/standard-jig-185/ it's pretty good, but could do with more holes to lock it in place.

  12. #52
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    got some panels today from Al, This is going to be fun...

    panels.jpg

  13. #53
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    spent a month on the rear end, everything is done, the caddy is 95% rust free! was a lot of hard work, i hate grinding...

    Pics galore, didn't take many of before pics, i forgot...

    before pics of the bed.

    caddy bed before 1.jpg
    caddy bed before 2.jpg
    caddy bed before 3.jpg
    caddy bed before 4.jpg
    caddy bed before 5.jpg

    Starting off removing the bed

    bed removal 1.jpg
    bed removal 3.jpg
    bed removal 4.jpg
    bed removal 5.jpg
    bed removal 6.jpg
    bed removal 7.jpg
    bed removal 8.jpg
    bed removal 9.jpg

    Removing rust in arches, and the welds..

    arches rust 1.jpg
    arches rust 2.jpg
    arches rust 3.jpg
    arches rust 4.jpg
    arches rust 5.jpg

    Welding up chassis rails and arches

    chassis rail weld rear 1.jpg
    chassis rail weld rear 2.jpg
    chassis rail weld rear 3.jpg
    rear arches 1.jpg
    rear arches 2.jpg
    rear arches 3.jpg
    rear arches 4.jpg
    rear arches 5.jpg
    rear arches 6.jpg
    rear arches 7.jpg
    rear arches 8.jpg
    rear arches 9.jpg
    rear arches 10.jpg
    rear arches 11.jpg
    rear arches 12.jpg

    Other side

    rear arches 13.jpg
    rear arches 14.jpg
    rear arches 15.jpg
    rear arches 16.jpg
    rear arches 17.jpg
    rear arches 18.jpg
    rear arches 19.jpg
    rear arches 20.jpg

    Grinding down cross members/chassis rails and adding new ones in.

    cross members 1.jpg
    cross members 2.jpg
    cross members 3.jpg
    cross members 4.jpg
    cross members 5.jpg
    cross members 6.jpg
    cross members 7.jpg
    cross members 8.jpg
    cross members 9.jpg
    cross members 10.jpg
    cross members 11.jpg
    cross members 12.jpg

    Grinding original paint from sidewalls

    side walls 1.jpg
    side walls 2.jpg
    side walls 3.jpg

    then the sketchy part of flipping car upside down and balancing it on wheels while i remove the rear end and leaf spring mounts..

    leaf spring mounts.jpg
    leaf spring mounts 2.jpg
    leaf spring mounts 3.jpg
    leaf spring mounts 4.jpg
    leaf spring mounts 5.jpg
    leaf spring mounts 6.jpg
    leaf spring mounts 7.jpg
    leaf spring mounts 8.jpg
    leaf spring mounts 9.jpg
    leaf spring mounts 10.jpg
    leaf spring mounts 11.jpg
    leaf spring mounts 12.jpg
    leaf spring mounts 13.jpg

    Painted

    leaf spring mounts 14.jpg
    leaf spring mounts 15.jpg
    leaf spring mounts 16.jpg

    had to do rear valance as it had awful patch work, forgot to take before pic...

    valance 1.jpg
    valance 2.jpg
    valance 3.jpg
    valance 4.jpg

    Moving onto bed, fixing up the bits i cut out earlier, were a bit of a pain.

    bed 1.jpg
    bed 2.jpg
    bed 3.jpg
    bed 4.jpg
    bed 5.jpg
    bed 6.jpg

    Preparing bed and plug welding it in!

    bed 7.jpg
    bed 8.jpg

    Adding strip to bulkhead end, and making 14 end pieces

    bed 9.jpg
    bed 10.jpg
    bed 11.jpg
    bed 12.jpg
    bed 13.jpg
    bed 14.jpg
    bed 15.jpg

    Welding it in!

    bed 16.jpg
    bed 17.jpg
    bed 18.jpg
    bed 19.jpg

    Very happy with it! got a few little bits to tidy up, but i think i'm pretty much there, welding wise.

    Next is body filler which im dreading, then paint.

  14. #54
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    Nov 2010
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    Devon
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    You've done a fantastic job with the rear end and load bed panel. Well done for doing the tapered end pieces on the bed, I chickened out of doing that with mine cos it looked too difficult to make it look neat but you have done a great job with yours.

  15. #55
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    Jun 2009
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    cornwall
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    1,825
    Awesome work mate,pretty much rebuilt the whole caddy from what I can see of it,you certainly won't regret it a few years down the line thats for sure....carry on with that standard of work and its gonna be a top caddy,hats off to you

  16. #56
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    May 2014
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    grimsby
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    Nice work dude, those bed tapers look good, well worth the extra effort

  17. #57
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    South Wales
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    Thanks a lot guys! the tapered end pieces weren't too difficult but definitely worth the extra time. Originally i wasn't going to do the bed, but it was definitely worth it, if its on the spit, may aswell do it properly while it's there.

    I do plan on having it look decent, but not perfect. what i am focusing on is mechanical side to be mostly all new if possible, want it to be like a brand new car.

  18. #58
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    Jan 2011
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    South Wales
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    Finishing up a few last bits of welding as my friend wanted his welder back after 4 months which was pretty nice of him to leave it with me that long.

    no more arches... they are gone, and i have a ton of room for some chunky tyres!

    arches fix 1.jpg
    arches fix 2.jpg
    arches fix 3.jpg
    arches fix 4.jpg

    Rear end of arches were both rusty, so cut that out and repaired it.

    arches fix 5.jpg
    arches fix 6.jpg
    arches fix 7.jpg
    arches fix 8.jpg

    Axle needed saddles back in original position, happy with the welds. (still need to cut off the bodged axle flip saddles)

    axle weld 1.jpg
    axle weld 2.jpg
    axle weld 3.jpg
    axle weld 4.jpg
    axle weld 5.jpg

    Putting back on the mount for the brake lines to go through, as far as i can remember it was something like this..

    axle weld 6.jpg

    Made new brake compensator bracket for the cross member as old one was rusted, ive no idea if i need this as im running mk2 golf rear brakes but it won't hurt being there.

    brake compensator mount.jpg

    Welding back in the exhaust hanger as i put in new crossmember

    exhaust hanger.jpg

    And finally seam sealing the underneath, used rubberised seam sealer, but switched to tiger seal and it's a lot better and lasts much longer!

    seam sealer 1.jpg
    seam sealer 2.jpg
    seam sealer 3.jpg

    and a sneak peak at the next task in hand... never done it before, but it's going alright.

    body filler 1.jpg

    Not sure how long it's going to take, but as soon as body filler is done i'm going to etch primer the whole thing.
    Will be painting for first time aswell, hopefully it turns out alright.

  19. #59
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    its coming on dude, hats off to turning your hand to the painting, not sure i have the confidence for it.

  20. #60
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    thanks, took a little longer than i'd liked but its better than i anticipated. by paint, i kinda mean etch primer and underseal the bottom.
    might paint the engine bay and cabin, but i don't think i'll do the whole body, not in my dusty shelter.
    only one way to learn, and that's to make mistakes

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