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

  1. #21
    Join Date
    Jan 2011
    Location
    South Wales
    Posts
    187
    Got a little bit of work done today, did a bit on my own aswell.

    Finishing up stitch welding the bay, still needs a few more bits, mostly done though.

    stitch weld bay 4.jpg
    stitch weld bay 5.jpg
    stitch weld bay 6.jpg

    Got 1 of the chassis rails welded in, looks really good, super strong, maybe too strong. Also need to remember to drill in some drainage holes just in case too.

    chassis rail plate 1.jpg
    chassis rail plate 2.jpg
    chassis rail plate 3.jpg
    chassis rail plate 4.jpg

    Attacked a rust hole all on my own, and plated it up, felt pretty good to finally do something on my own!

    rust plated 1.jpg
    rust plated 2.jpg
    rust plated 3.jpg
    rust plated 7 (meant to be 4th).jpg

    I lost 1 of my magnets into the abyss of the rust hole, forever lost.

    cut out the rust and plated the jacking point, been using 2mm thick steel, so very strong.

    rust plated 4.jpg
    rust plated 5.jpg
    rust plated 6.jpg

    That's all i managed to do, pretty happy with the work i did for i think my 3rd or 4th day of welding!
    I'll grind some of the welds down as they don't look the best, but that's the beauty of it!

    1 thing i wish i did was clean and red oxide as soon as i weld an area up, some of the stitch welds are starting to rust, 1 thing to note.
    Tomorrow im working on my own, doing the other chassis rail and cutting out the other jacking point, little nervous, but i'll give it a go!

  2. #22
    Join Date
    Aug 2015
    Location
    Romsey
    Posts
    553
    You'll do fine. It's all looking good.

  3. #23
    Join Date
    Jan 2011
    Location
    South Wales
    Posts
    187
    i think i'm going to just make sections for the other jacking point and few holes, i won't touch this, if i mess it up, the wishbones wont lineup properly.. i've no idea where i'd even start with it. such a tricky spot.

    chassis rail removed 3.jpg

  4. #24
    Join Date
    Aug 2015
    Location
    Romsey
    Posts
    553
    I really struggled with that spot. I did it in 2 parts to ensure that one part was always secure. Then I tidied it all up.

  5. #25
    Join Date
    Aug 2015
    Location
    Romsey
    Posts
    553
    There's a some good advice given on #102 on my build thread.
    I tried to add it to this post but to no avail.

  6. #26
    Join Date
    Jan 2011
    Location
    South Wales
    Posts
    187
    i think i'm going to avoid that piece.. i got some great info from your thread though, thanks a lot! this seems like a job for my friend, he did say to double plated it, but im thinking it needs a thinner plate over the top of that aswell, like this:

    floor welds 5.jpg

    previous owner kind of did that on the other side, ill also measure how much thread is on each bolts to see if they match up.

  7. #27
    Join Date
    Jan 2011
    Location
    South Wales
    Posts
    187
    Today i made a mistake, i was welding and the welds were spluttering, they looked ok, and i thought nothing of it, it wasnt till my last weld that i realised.. the gas wasnt on
    So my clothes are covered in holes and my arms have burn marks all over them, i think the welds are strong? i held them on a bit longer than usual, hit it with a hammer a bunch and it held so hopefully everything is ok..

    With that said, here's the pictures..

    jacking point cut 2.jpg
    jacking point cut 3.jpg
    jacking point cut 4.jpg

    Made plate and welded in (had to use a big magnet as i lost all of mine)

    jacking point plate 1.jpg
    jacking point plate 2.jpg
    jacking point weld 1.jpg
    jacking point plate 3.jpg
    jacking point weld 2.jpg

    grinded welds down, looks.. ok?

    jacking point smooth.jpg

    Cleaning the jacking points and spot welding them back in

    jacking point spot weld 1.jpg
    jacking point spot weld 2.jpg
    jacking point spot weld 3.jpg

    Kinda disappointed i made the mistake, but now i know i won't make that mistake again..
    can someone comfirm my welds are strong? i was melting the edge of the 2mm thick metal so i assume it should still be very strong.
    i did go over a few of the welds when i turned the gas on aswell, maybe i need to do that again? im not sure.

  8. #28
    Join Date
    Apr 2014
    Location
    North Wales
    Posts
    1,563
    Have to ask why are you stitching the seams ??
    Life is just a game we play!!

    My build http://www.vwcaddy.com/showthread.ph...er-cover-caddy

  9. #29
    Join Date
    Jan 2011
    Location
    South Wales
    Posts
    187
    Strengthening the chassis so it handles better, i presume. i'm just going with the flow of what my friend tells me, he built a mk2 escort and it's pretty amazing.

  10. #30
    Join Date
    Apr 2014
    Location
    North Wales
    Posts
    1,563
    Yeah it was what we used to do to rally cars years ago
    Life is just a game we play!!

    My build http://www.vwcaddy.com/showthread.ph...er-cover-caddy

  11. #31
    Join Date
    Jan 2011
    Location
    South Wales
    Posts
    187
    i can't see it doing anything negative, other than possibly cracks showing up if you hit something hard, the caddy was in an awful state, bodged everywhere.
    Not too worried about wrecking anything, i think it'll be super strong when it's done, just a little bumpy!

  12. #32
    Join Date
    Apr 2014
    Location
    North Wales
    Posts
    1,563
    I dont see any problem with it just had to ask im the champion of overkill lol
    Life is just a game we play!!

    My build http://www.vwcaddy.com/showthread.ph...er-cover-caddy

  13. #33
    Join Date
    Jan 2011
    Location
    South Wales
    Posts
    187
    haha, yeah, we probably made it maybe too strong, especially the chassis rails, even with a few tacks it didnt move at all. you live and you learn, not the end of the world.

  14. #34
    Join Date
    Apr 2010
    Location
    cornwall
    Posts
    138
    that's coming on nicely, did you notice the loose pipe in the fuel tank? same happened on my caddy sport and it would cut out when it was less than 1/2 full. if you need a chassis rail I have one I cut off a breaker also have the exhaust tunnel with handbrake tubes P1000237.jpg

  15. #35
    Join Date
    Jan 2011
    Location
    South Wales
    Posts
    187
    yeah i managed to get the pipe out! i made my own chassis rail just got to weld it in, i'll figure out the handbrake tubes, but how do i take them off? do they just twist off or what? Thanks for the advice!

  16. #36
    Join Date
    Jan 2011
    Location
    South Wales
    Posts
    187
    Got the last chassis rail done today, floor is looking pretty good, few bits to do and the sills then it's finished!

    wishbone mount 1.jpg
    wishbone mount 2.jpg
    wishbone mount 3.jpg
    wishbone mount 4.jpg

    welding in the strips for the chassis rail to sit on

    chassis rail strip 1.jpg
    chassis rail strip 2.jpg
    chassis rail strip 3.jpg
    chassis rail weld 6.jpg

    Ran out of welding wire, burnt through about 3kg of it in a week, not too bad!

    Got some red oxide to brush on £30 for 5litres! great stuff floor is looking really good now

    floor painted.jpg

    Was getting late so couldn't clean up some areas to paint, but its almost there, chassis rail needs some welding as we ran out of wire, should be done tomorrow.
    Very happy with the progress, theres some stuff to do in the engine bay, big rust hole in the floor in the cabin then i think it's onto the dreaded rear..

  17. #37
    Join Date
    Jan 2011
    Location
    South Wales
    Posts
    187
    Didn't like the way the other inner front arch was done, so cut out the 2 crappy patches and started making plates, stitch welded the turret aswell.

    drivers inner arch 1.jpg
    drivers inner arch 2.jpg
    drivers inner arch 3.jpg
    drivers inner arch 4.jpg

    Trying to stitch weld the turret but the metal was just rotton, so cut that out

    drivers turret 1.jpg
    drivers turret 2.jpg
    drivers turret 3.jpg

    Smoothed off some welds from previous owners patch, the only one im going to leave in and hope and pray its decent behind it..

    smoothed weld 1.jpg

    Will probably go over it tomorrow, also forgot to show we welded 1 plate in, but didnt manage to get the other one done.

    Brother was using poly disc on rear quarter to bare metal, doesnt heat it up much or distort it, so very handy thing to have! only took a few hours!

    bare metal quarter 1.jpg
    bare metal quarter 2.jpg

    Used roller to paint it with red oxide, came out pretty great!

    quarter painted.jpg

    Painted both inner front arches, painted it on thick

    inner arch painted.jpg
    inner arch painted 2.jpg

    Forgot to take pics of some things, finished the chassis rails, bottom floor is almost done, need to fix the sills and then it should be good!

    few bits to fix on the inner arches still, but very close to being done.
    Next is finishing the engine bay stitch welding and a few rust spots, then the cabin needs some work from welding the floor.
    Few more days hopefully!

  18. #38
    Join Date
    Jan 2011
    Location
    South Wales
    Posts
    187
    Well, it's been a while... been busy doing odd bits and figuring out things. here's a lot of pictures of the work i've done over the last month.

    Grinding down to bare metal

    Attachment 32536
    Attachment 32537
    bare metal 5.jpg

    red oxided

    painted 1.jpg
    painted 2.jpg
    painted 3.jpg

    Grinding windscreen surround to bare metal and repairing rust

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

    Fixing it all up

    windscreen fix 1.jpg
    windscreen fix 2.jpg
    windscreen fix 3.jpg
    windscreen fix 4.jpg
    windscreen fix 5.jpg
    windscreen fix 6.jpg
    windscreen fix 7.jpg
    windscreen fix 8.jpg

    rear window bulkhead

    Attachment 32533
    Attachment 32534
    Attachment 32535
    rear window bulkhead 4.jpg
    rear window bulkhead 5.jpg
    rear window bulkhead 6.jpg

    Finishing up the inner front arches

    inner arch 1.jpg
    inner arch 2.jpg
    inner arch 3.jpg
    inner arch 4.jpg
    inner arch 5.jpg
    inner arch 6.jpg
    inner arch 7.jpg
    inner arch 8.jpg
    inner arch 9.jpg
    inner arch 10.jpg
    inner arch 11.jpg
    inner arch 12.jpg
    inner arch 13.jpg


    Stitch welding cabin

    stitch weld cabin 1.jpg
    stitch weld cabin 2.jpg
    stitch weld cabin 3.jpg
    stitch weld cabin 4.jpg
    stitch weld cabin 5.jpg
    stitch weld cabin 6.jpg
    stitch weld cabin 8.jpg
    stitch weld cabin 7.jpg
    stitch weld cabin 9.jpg
    stitch weld cabin 10.jpg


    Cutting out sills and fixing up the rust

    sills 2.jpg
    sills 3.jpg
    sills 3.jpg
    sills 4.jpg
    sills 5.jpg
    sills 6.jpg
    sills 7.jpg
    sills 8.jpg
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    sills 18.jpg
    sills 19.jpg
    sills 20.jpg
    sills 21.jpg
    sills 22.jpg
    sills 23.jpg
    sills 24.jpg
    sills 25.jpg

    Rear sills

    rear sill 1.jpg
    Rear sill 2.jpg
    rear sill 3.jpg
    rear sill 4.jpg
    rear sill 5.jpg
    rear sill 6.jpg
    rear sill 7.jpg
    rear sill 8.jpg
    rear sill 9.jpg
    rear sill 10.jpg
    rear sill 11.jpg
    rear sill 12.jpg
    rear sill 13.jpg
    rear sill 14.jpg
    rear sill 15.jpg
    rear sill 16.jpg
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    rear sill 18.jpg
    rear sill 19.jpg
    rear sill 20.jpg
    Attached Images Attached Images
    Last edited by Nick-Nack; 25-05-2018 at 08:28 PM.

  19. #39
    Join Date
    Jan 2011
    Location
    South Wales
    Posts
    187

  20. #40
    Join Date
    Jan 2011
    Location
    South Wales
    Posts
    187
    worked on the rear turret sills today, got quite a bit done, hoping, possibly tomorrow i can finish it all and even weld on the sills, but that's pushing it.

    rear turret.jpg
    rear turret 2.jpg
    rear turret 3.jpg
    rear turret 4.jpg
    rear turret 5.jpg
    rear turret 6.jpg
    rear turret 7.jpg
    rear turret 8.jpg
    rear turret 9.jpg
    rear turret 10.jpg
    rear turret 11.jpg
    rear turret 12.jpg
    rear turret 13.jpg
    rear turret 14.jpg

    Need to clean the turret up a bit but it looks like it's going to fit back in place just nicely.
    I'll see if i can finish it tomorrow, but im happy with the work so far looks so much better.

    Anyone have any tips on removing the surface rust from the tight spots? my dremel is pretty awful.

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