mk1 caddy 24v turbo 4wd project ,stress...56k warning

[powernut]

hi all i know this is gunna be stress but id thought id share ,as i may need some advise on this buggar,as ive facied a caddy for a while and always liked the mk1 golf caddy shape ,it was only when i went and called in at a local farm and found a mk1 caddy been used with a forlk life for a gate post,,coverd in nice green mold,so after chatting with the farmer i bought it ,as its in a poorly state at mo due to been stood for 7 years ekkk:(,so i eveturly got it home ,with nice brakes burnt out ,and sized wheels ,,

plenty of holes and rot too,along with holly floors too

so after a 2hour wash ,i can see potentioal

and that horried back is going plus the old 1.6 diesal and gearbox is too

so next thing i thought i need a power house ,and thought id do some modifaction to get a nice mk3 vr6 in it ,

yes i know these dont fit by just bolting in more mods are needed ,
then thought it will make the front end heavy so thought ill buy a complete 2001 mk4 golf 4 motion rear axle for some extra grip


asi was only going to make it 2wd drive ,i thought id better make it 4wd so bought a nice 02m 6speed gearbox to fit to my 12v vr6 lump

then sorted a proshaft and some spare drives etc

then thought these engines are only 174ish bhp ,erm and id had the ecu chipped to 200bhp i still wasnt happy ...so i thought id buy a transfor box and turbo kit etc for my set up

[Vento Mike]

This is gonna be a hot one baby! Looking forward to seeing more

[powernut]

then fitted my gearbox starter ,part turbo kit and 4wd transfor kit to the engine

,thought id basicly get all the runing gear sorted saves hunting around at a later stage ,then i hit a small prob ,the rear golf axle is not only too wide but the ecu is called haldex and needs a controller to work ,this part from dealers called haldex ecu is 600..that just for this little box

and beteen 600 to 850 for a part to control the 50/50/50/100 all time 4wd system,so i thought chuff that ill make my own,after a bit of stress ive sorted the curcit ,stepper,and controller to make it work nice ,for either raceing or daily driveing,,
then dropped on some mk3 coil overs which im hopeing i can use mk1 top mounts,then shortern drives ,a arms quick pic here

just built the meqa squirt ecu up and cranked the engine and put a map on the ecu so it should run in theory lol,,,

and thats as far as ive got within 2 weeks im affraid but there will be plenty of burning welding filling .modifying to come,,,,

[powernut]

oh i dint know mk4 r32 drives bolt sraight up in mk3 hubs saved a little job

and slightly skimmed the inner alloys to dish ,so they nicely miss the rear calipars and rear dampers

all fits well

and some alloys ther will have to do with a quick refurb at a later stage

[powernut]

i thought id make a manifold for the caddy vr6 and heres how i did it ,,3hours all done ,im just unsure which way the thottle body is supose to be,,
bit of drawing first

then a bit of drilling

bit of grinding

welded bolts in place

cut some tube and welded some steel

end plate for thottle body

quick grind around

grind ed it up


job about done ,just a couple of pipes and thottle hanger

i hope theres enoegh pics for u ...


unsure how close it will be to the front ,as i just gessed,,,



lol its usely the case small things take longer then the buigger jobs

well,lol if u think were poeple use fit the turbos on the vr6 ,the turbo,downpipe,manifold get really hot ,and the intake is bang above,so its like a big heat sink along with under bonett and hot compresed air ,so u make one of these thow it on, and it thows direct air into the engine, and takeways all that hot ait and heatsink,so u get a better turbo pull and low induction temps,
colder the air better the power gain ,hotter the air more the engine lacks and runs crapy,,,

right this afternoon i had to go and see if it would fit bolt up and weld servo and fuel reg pipes on fit and looks ok for a first attempt


evern pipes fit o too

then thought we might as well that manifold will be hot so make a quick cover for it ,a bit of bling or somert like that


fits ok ,

be nice when im ready to mod the turbo too,,,may look a bit more like a engine lol


little update not too mutch as im still filling the bug ,but i had a few hours spares so i noticed this pipe and im sure this is why i had a water problem ,

anyway i went and bought a r32 golf thermostat houseing so i cann select 5th and 6 gear due to the std vr6 themostat was in the way

these are the too houseings

then made some bolts

nice fit in the r32 houseing

notice the std vr6 and the r32 tube lengths

so houseing pipeing fitted and std vr6 sensors fit in the houseing too

decided i dinr want power steering so removed all that along with the aircon bracket ,so i can add somert at a later stadge to the engine

belt pulleys sorted

decided to use differnert type of ht leads


and polished rocker as well tidys things a little
[/

[powernut]

Originally Posted by Vento Mike

This is gonna be a hot one baby! Looking forward to seeing more

unsure bud never drove one of these buggars ,,but one we will find out i reckon, i dont think the scoobys fans will be too inpressed ,when i pass then like there doing 40 lmao...

[powernut]

some engine problems,got the engine runing on the floor,and 10mins of runing ,a horrible noise came on ,so its bloody strip down again ,stress,mind im glad it wasnt all fitted and this happernd on a test run..




problem a little end on one piston and i need some more piston skimming too,,for more boost.and timing chain guid smashed
so made the flywheel fixed ,to make sure it will hold bhp


aint done ought to the bug ,as i didnt want the engine full of dust,
started building engine engine back up 2day ,as i thought chuff the head spacers ,get the lathe out and skim em lol




more engine build ,,,carnt wait to start the dam caddy lol



therd some bolts and bit of welding for the flange

[Jon P]

looks like an awesome project,

had thought of doing this when i had a caddy, but i have no skills in fabbing such stuff up!

good luck with it!

[2dubnick]

wow mate good skills, look forward to seeing this come together.

[ihaveajetta]

so awesome man!!!!!! keep it up

[fthaimike]

cracking stuff, keep the updates coming

[powernut]

bit more modifying done this after
had to make a head spacer needed the compression lower ,,

then its start chopping the rear axle to size

rewelded it up in place

then got a bit ampage on the go ,,i dont want these snapping off

axle shorternd

next antiroll bar needs shorterning so instead of choping welding ,i decided to heat and bend it



sorted
double checked measurement

just a mock up with the caddy tailgate ,and it should fit,,


not mutch to add due a nice hangover from the night before lol ,so just tacked the short runner pipes up


made a return pipe ,had to weld it in 5 places to get it right



right after trying 7 differnert headgaskets i finaly got a steel one to fit lol ,so carried on with the homemade headspacer ,chuff buying when u can make one

so carried on with may home head spacer lol


once the runing gear is sorted ,its caddy modifying time

a small change in plans lol ,im not going to use a old mk3 vr6 turbo ,that ill go on ebay ,ive decided to try attempt fit a later mk4 4motion 24valve engine and turbo that instead ,so started again as im more happy with this idea so heres what i bought,as i couldnt leave it right bargin..


head off all valves re seated and skimmed

ill be makeing another turbo manifold,inlet manifold,etc

starterd on the manifold 2night had to do somert

think it may work..
injectors arrived 2day
.
erm lots of fuel useage lol




thats the manifold turbo about sorted,
next time to start and make another dam inlet manifold,,,lol
once thats something like useable i want to get the buggar runing on the floor make sure we have boost lmao



COUPLE OF MODS THIS AFTER sorted oil feed and couple up,remove old cam sensors ,ill not need them made a plate ,
fitted coil pack
next i need to get the ecu sorted and wireing




IM CHUFFED HOW TURBO IS SAT ,NOT TOO HIGH so bonnet should shut in theroy lol


JUST BOUGHT MY STANDALONE ECU AND WIREING HARNESS ANOTHER BARGIN.....



modifyed some nice decent size cc injectors ,


intake manifold to make next ...
and a few tuning bits arrived too,,

also added lunch control for tracks and a stand alone rev counter ,,

[NigeP]

Bonkers !!

I like it a lot !

[paulyb]

Pure mental, I salute you! Cant wait to see it finished, are you leaving the bodywork as it is?

[powernut]

Originally Posted by paulyb

Pure mental, I salute you! Cant wait to see it finished, are you leaving the bodywork as it is?

cheers guys ,yep ill sort the welding etc ,but ill leave it rough ,just a quick home made idea ,as it will end up were it started , ,may get a little more done 2moz wheather permiting ....

[Chris Eyre]

This is looking like a pile of Scooby trouble indeed!

Some great fabbin skills - just promise us you'll finish it. Nothing's got in your way so far

[badger5]

great read.

looking fwd to next installment

[jaswan]

very nice work mate, its gona be a right stealth flyer.

Jason.

[AngryBob]

Is that head spacer part of the Disney club?

[PhatVR6]

lol! nuts

check out the 3.2 sump thread i started on vr6oc if you're having clearance issues.

[powernut]

bit of work started on the caddy this after rip the rear hood off ,ripped the oil 1.6 oil burner and box out exahust off ,gearlinkage out
pedal box out,found a few more rottern parts eg rear floor,rear roof,bits on inner wings ,







few mock up pics of were ill roughly fit it




as u can see fitting this isnt going to be hard at all ,
bit of cutting choping here and there and that bit ill be mounted ,
then ill mod the power steering as well,
rip the tunnel out ,fit another ,algine prop ,and adapt tthe rear axle ,,
everthing ive thought off so far isnt no were near as bad as first thought,

bit more done on the mk4 turbo lump too,,,

oil return sorted and a start on the inlet manifold this afternoon

home made oil pipe,every little bit comes in


removed sumps as the early steel one fits and is cheeper to replace if i hit a hump lol



engine comeing along nicely now ,,,



soon be ,,caddy moding time ...carnt wait ,,,lol like a kid in a sweet shop

[2dubnick]

I think this is the fastest project CGTi has ever seen cant wait to see the rest of it coming together

[powernut]

Originally Posted by 2dubnick

I think this is the fastest project CGTi has ever seen cant wait to see the rest of it coming together

nice thought but i woundnt go that far ,theres some real quick v dubs on around,,,have to say though ,at some point im going to have real tracksion problems over 400bhp lol ,ive evern got my fuel maps set up enough fuel to run 560bhp ,,,just fitted a sweet 4bar map sensor too ,probley never use it ,but i supose its there if needed ,,,,cool reply ,,,

[nealey]

What a project and well done!

There are some serious projects going on atm!

[2dubnick]

lol i actually ment the fastest progressing, but it will also be one of the faster dubs about aswell!