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Thread: Working on MK1 Caddy Lower Bulkheads!

  1. #1

    Working on MK1 Caddy Lower Bulkheads!

    These have been obsolete for years, but I was kindly given a centre section of Caddy, so I have carefully unpicked all of the welds (took forever) so now im we are in the process of prototyping a complete replacement panel.

    The forming is now done for the square sections, so should have a full prototype panel by the w/end :music:

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    Watch this space

  2. #2
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    No mystery holes? these will be US spec?

  3. #3
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    nOICE

  4. #4
    Quote Originally Posted by regcheeseman View Post
    No mystery holes? these will be US spec?
    Yes will be "US Spec", but you can always rivet on a cover if the oem look is wanted. TBH if someone really wants the holes they can be laser cut for the anoraks noproblemo

  5. #5
    Struggling with some distortion at the moment, so onto plan B

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  6. #6
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    not bad for a first attempt though mate

  7. #7
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    Quote Originally Posted by Al View Post
    Struggling with some distortion at the moment, so onto plan B

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    One end looks fine or is it the picture?

    I take it they are pressed one square at a time, did you start from one end and work along the panel as the distortion looks cumulative, try pressing centre squares first and work out?

  8. #8
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    :thumbs_up I may require one of these when I finally get my teeth stuck into mine.
    Fun Size... I dont get it. What's so funny about half a mars bar?

  9. #9

  10. #10
    Quote Originally Posted by regcheeseman View Post
    One end looks fine or is it the picture?

    I take it they are pressed one square at a time, did you start from one end and work along the panel as the distortion looks cumulative, try pressing centre squares first and work out?
    Yes, one square at a time, and thats the problem, the originals are stamped in one hit in a mould. The problem is the depth and when you do more than one it drags in so much steel that distortion is unavoidable!

    The solution was to slightly reduce the depth of the squares

  11. #11
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    Looks good

    Can't you just buy the old tooling from VW and start banging out new caddys.

  12. #12
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    Very nice. Great work on another bit for the old shitters :thumbs_up

  13. #13
    Quote Originally Posted by regcheeseman View Post
    Looks good

    Can't you just buy the old tooling from VW and start banging out new caddys.
    I wish! Tooling has probably long been scrapped.

    There is a Chinese company banging out new MK2 Escorts shells now. An Irish fella is fronting it, he sent them a good shell and they reverse engineered it




  14. #14
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    Holy fuck!!! I love the Chinese :thumbs_up

  15. #15
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    Quote Originally Posted by Al View Post
    Pretty much there

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    Looks superb alun, you should be really proud

  16. #16
    Ok, so I have sent my metal expert mental in the last week or so trying to get these bulkheads as best we can.

    He has had problems with distortion and all sorts so unfortunately we have had to compromise on these a bit. The depth of the stamping on the original part is 6mm deep, but we have had to reduce this to 4.5mm to keep the distortion to a minimum. Even at 4.5mm the panel is still a little bit live but that will sort itself out once welded in.

    So here is a completed prototype, we have just got to sort out the costs now, so will update you as soon as I know.

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    Also full depth inner/upper bulkheads are now available in the shop as well as the half depth ones

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    http://www.retrofication.co.uk/bulkrepinnerfull.html

  17. #17
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    looking good Al

  18. #18
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    I wish all these panels were available when i did my caddy. I had to hand make the rear lower panel, bed cross members and upper part of the bulkhead. Now i can buy them for peanuts. Great work Al

  19. #19
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    having just found a bit of rust in my caddy, i'm so glad i've waited until now to get it sorted. next couple of months you will be getting a large order from me Al!

  20. #20

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