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Discussion Starter · #1 · (Edited)
BoosteOne's Caddy Build

I'm gettin to old for this:D But I love it.
Long story short, I commute about 85 miles a day for work. I have a nice new car to drive, but its racking up miles at sickening pace, and the best I can manage out of it is an average of about 23mpg. I don't want to drive my dually as a daily because, well, it only gets about 18. I was considering getting my MkII VR resurrected, but that thing only gets around 23...

So, on July 26th, I picked up my new project. a 1982 Caddy Diesel with a broken timing belt. Body is in fair shape. From what I could tell, body was in decent shape. Shock towers seemed solid, floors seemed good.. Had some rust bubbling though in one fender, one A-Pillar, and one B-Pillar. Its a 5 speed truck, with a gutted dash.
Plans are get the 1.6D running again, but later replace it with a 1.9TDI or AAZ.. Roll on 14x8 and 14x9s and coils and rear axle flip. Paint to be BMW Leguna Seca Blue.. I have a friend with an 01 M3 and I love the color.
The rest of the details will sort themselves out.. But I originally planned to have it repainted and together by the first week of October or so..

Here she is when I first got her...

July 26:
Still on the trailer as I day dream with excitement through the back window..


Got her offloaded into her temporary parking spot out back. The truck came with 2 bed loads(the caddy and my dually), and a cab load of spare parts..
Interior Looks pretty good.. Too bad theres nothing behind the dash..








The very, uhhh, lively painted 1.6D


Since I have always preferred round lights going back into the mid 90s, first thing I did was source a round headlight swap. I found a wrecker who had a 90 Cabby that was in pretty good shape. I ended up buying the front clip. Since there is nothing behind my dash, and hard top rabbits that arent already half stripped are getting harder to come by in these parts, I also decided to get the dash, A/C stuff and all.. So the Caddy will be getting a Cabby dash swap.
 

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Discussion Starter · #3 ·
Due to the ton of new parts, for the first week I didnt get to actually work on the truck. I had to organize my storage connex and build new shelves.

But by first week of August, I had the new clip.


August was a rough month. I got slowed down pretty bad. Work has gotten really busy, and I have cows. One of them got pretty sick and took constant care for a week until she died, then I had to deal with that. This is also grass growing season, the stuff grows like mad this time of year and cutting it takes all weekend every two weeks.. It didnt help that the mower threw a rod through the side of the block, so I had to shift gears and drop 1800 clams on a new engine for the mower and get that installed and working and caught up around the property.:banghead:

SOOO, finally in late august I start working on the truck.. Got her inside, and threw the Clipper bumper on it just to see what it fit like... Not sure Im crazy about it.. But hey, it was included with the clip so I figured I would atleast look..


August 15 I start actually getting going on the truck. Out comes the motor...






Get over to the new clip, and start working on that..
I used a torch to hack the frame rails down by the mounts, then gradually cut the frame rails away from the cross member in little peices in order to leave the round light cross member un hacked.





I didnt get any pics of it, but from there I drilled out ALL the spot welds between the inner fenders on the donor clip and the core support, and the spot welds holding the cross member to the inner fenders

August 17th, I moved over to the truck.. I did just the opposite to the truck, removing the Westy core support in sections in order to preserve the frame rails and inner fenders.







August 18, got the new core support test fitted and tacked in!

 

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Discussion Starter · #4 · (Edited)
Over the course of the next week, worked on work, house, etc. Managed to get the core support welded in.

On August 25, pushed the truck outside for a date with the sandblaster.. Rather than sit and try to strip all the paint from the engine compartment, I just blasted it..




The interior looks like a beach!


Got it back inside, and the next day I got a coat of epoxy primer down...





While I was on a roll, went ahead and blew the paint in the engine compartment :D:D:D
BMW Leguna Seca Blue:D






On August 30, moved on to the fenders.. Deleted the marker lights and the antenna hole.



I actually thought at this point the hard part was done, and that I would breeze through the rest of the truck.
Between the 30th and the 7th, I stripped the interior, the glass, and pushed the truck outside and blasted the rest of the rust..

Welded a patch in the A Pillar..





Cut out a section to patch in the rear of the cab..


I didnt get any after pics, but heres the hole in the B pillar.. previous owner was nice enough to use VW in a can(Bondo).. I hate that halfass crap.. I will say making that patch across 3 body lines in 5 inches was FUN...WITH A CURVE..

 

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Discussion Starter · #5 ·
Between the 7th and the 16th.. This thing sucked..LOL.. Like I say, I thought the hard part was behind me.. But no.. it was a tedious week of sanding, smoothing, and more sanding.. I managed to get the A and B pillar done and interior patched. That was the fun part.. the crappy part was the previous owner painted the truck with some cheap acrylic enamel.. The stuff just laughs at 220 or 180 grit... I ended up stripping through several layers of enamel and primer using 80 grit on the DA.. It was just a pain because the truck was covered in chips(what else is enamel good for other than chipping!).. Feathering all these chips was a pain in the buttocks..






The previous owners love affair with bondo extended to the flair holes, which were bondo'd shut..

SAY NO TO THE BONDO! LOL....
Welded the holes shut...


I don't know how much filler the previous bonehead went trhough on this truck, but after shaving the side markers, antenna hole, repairing the A pillar and b pillar, the wheel wells, and hammering out various dents, I've used less than a QUART of filler on this entire truck.. That includes half of it ending up on the floor in the form of dust and what ended up in the trash can not used after being activated..
 

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Discussion Starter · #6 ·
THIS WEEK THINGS GOT INTERESTING:D:D:D:D:D:D

Of the more not so fun, I continued sanding and priming...YAWN....

BUT, my wheels started showing up on the 20th.. 14x8 and 9 Steffan Cups.. Bald 195-45's in the front, 225-40s in the rear. Unfortunately as of today, the 23rd, one rear wheel still has not shown up, and theres no tracking update since Germany on the 8th... I hope it isnt lost:(








Yesterday I finished sanding the shell and fenders, as well as tried to help gsusmaniac try to get some bolts out of his manifold..Sorry Erik that it didnt work out....

Today the truck got rolled outside and washed....



IN PREPARATION OF PAINT!! I feel like a giant weight just came off my shoulders...


No more rust holes!




I couldnt resist putting the stuff together tonight, even though I was exhausted from working on the truck every waking moment that I am not at work the past several weeks.














Next I need to get the doors stripped down, cleaned up and primed.. The hood is in pretty good shape and already degreased, ready to prime and paint..
I actually had the tailight fillers ready to paint today, and the first batch of paint was all messed up and made a mess of the fillers.. so I get the strip them, and redo...

Then on to mechanical. The brakes are shot, wheelbearings are shot, suspension is shot(found some ground controls in the junkyard, but they are cranked all the way down and I still have a gap too).. need to do the rear axle flip, etc.
Going to try to get the rest of the body panels painted this week and maybe start messing with the engine.. Goal is to atleast have it mobile for the MkI GTG in st augustine October 13..
 

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Discussion Starter · #12 ·
Thanks yall. Its been stressing, LOL..
I want to go to the show so bad on the 13th, and it would suck to go without it so I am pushing myself like crazy to get it there one way or another..

I hope the 3rd wheel comes in too! But in case it doesn't, whats the deal with 16s on a MkI? I have 16x7 and 16x9 keskins with 195 40's on my MkII I could put on the truck. I think I heard they don't fit, but why? I think the OD is the same as a stocker..

Going to run over and get the head from one of the engines that came with the truck checked for flatness in a few minutes. The truck came with the engine that was in it, a spare block and head, and a complete motor and tranny from a 1.6L MkII. I have no history on it. The timing belt was off it, so I was thinking it also slung a belt, but the pistons look fine. Im hoping the head is flat, because its a hydraulic lifter engine. I havent had a solid lifter car VW since the early early 90s, so I dont have shims and the tools laying around anymore. Would be nice to freshen up a hydro headed motor than the solid..

Tonight, not sure what I am going to do.. Probably sand the base coat eff up off the taillight fillers, and maybe start prepping the hood.. I ran out of clear coat so I need to order more.. My blaster needs a part, need to get that too.. Once i get the blaster part, I can get the doors ready.. Im not going to mess with trying to strip them with paper, I lose motivation just thinking about that.

How do you remove the vent windows? Are they riveted in?
 

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Discussion Starter · #13 ·
At first I wasn't sure how Laguna Seca Blue would look. But now after seeing it on the truck, that looks awesome. I am excited to see it with the suspension dialed in. :beer:
Yeah, I pondered about color for a while.. I was trying to think of something other than blue since I have done a bunch of blue cars, and I own a few of them now. I was wanting something that would stand out, but not TOO much.. Low key but still pop, if that makes sense..
Then one day I was coming back to the office from my jogging, and as I came through the parking lot I saw my buddies M3 there and I pictured it on the caddy. That was it!
The pics really arent showing the hue all that great in my opion. It actually has a little teal to the color, which is one of the reasons I picked it because its not "just a blue", LOL...
 

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Discussion Starter · #16 ·
Thanks y'all.
Didn't really do anything yesterday on the truck. I think I was wore out from the weekend.
Only thing I did(if you can call it doing something ) is take a head into a shop to get it checked out. On that note though, I think they are phucking me.... its like 220 bucks to have the head cleaned up and a valve job, plus parts. I was so tired when I dropped it off it didn't even hit me. Going to call another shop this morning that i really like, and if they give me a better feeling im going to pick it up and take it to the other place even though its way across town.

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Discussion Starter · #17 ·
YES!
The last wheel arrived and is waiting to be picked up! Figures that yesterday I went through a huge pain to get a tracer put on the package with the Duetsche Post since the last update for the past 3 weeks was like the second step of the journey.



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Discussion Starter · #20 ·
Thanks!
Trying to figure out what im going to do for an engine.. Just got the call from the head shop.. to get the head done is going to cost 657$. needs 8 valves and 8 guides.
I want to keep it a diesel, but I dont want to have over a grand in a na 1.6... But I dont have the money laying around to make it a TDI either..
I guess in the mean time I will throw the 2.0L 16V out of the other caddy in there while I figure it out.. :(
 

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Discussion Starter · #24 ·
Well, everyone around here gets about 250 just to do a "valve job".. ie, clean up and check the head, surface, and cut the seats...
Everyone charges about 15 bucks a hole to press in the guides, which from what I understand need to be reamed after installation.. Thats 120, up to 370..
Plus the price of the guides and valves..
Even at 400, its more than I want to spend right now...

As far as not wanting to take the 16V back out...Hmm, I probably wont be too attached to it.. LOL.. I never really been all that in love with 16V's.. I used to have one in the late 90s. It was ok.. But it wasnt all that great so I converted it over to K jetronic with lambda, it got a little better, then put a turbo on it, then ripped it all out and went 8 valve turbo with 8:1 compression 1.8 and an ABA head and standalone EFI.. at that point I was happy.

I just cant see putting the money in the 1.6 though.. Even if I could have the head back for 400, still need to freshen the bottom end, and no real idea if the injection pump has a bunch of life left in it.. I will be over a grand in no time, for a 1.6 NA..

Ooo, just remembered.. Some dude had a 1.6 on a local unrelated forum for 500 over a year ago and he still has it.. he still wants 500 for it, but I forgot all about that.. Maybe I will give him a call and head down south!
 

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Discussion Starter · #26 · (Edited)
whats the condition of that 16v? i want to put one in my truck one of these days:D

It's decent. 2.0L 16V running on Rado Digi 1. Depending what I do with that caddy, it may keep it as is, or get swapped over to a non forced induction ECU, or turn into a 16VT, or become a 20VT on a standalone...




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Discussion Starter · #28 ·
Haha Erik. If I make it you gots no excuse lol...

So today the last wheel came in. Was going to make up a shopping list for parts to put on the credit card and got side tracked...

I decided to do a zero dollar axle flip to even out the stance... not only did I go this route because im a cheap ass, I just don't like the bolt on kits from an engineering stand point....

After the axle is removed notice the locater pin. The round part is obviously on the bottom of the spring because that's where the axle was. This needs to be flipped to the top..





Now the round part of the pin is on the right side of the spring...



Then used a cut off wheel to get the spring plates off of the axle...



Notice the axle has holes in it for the pin. I placed the plates on the spring to see how much they protrude. The barely stuck out of the plate so rather than drill a pair of holes I wasn't sure where to put in the beam, I decided to shave the pin down with a 5" sander... I only took off maybe 0.030".....



After that centered up the beam and bolted it in...side to side I centered it up to the old rust lines left on the beam by the u bolts...
I remember people saying that they noticed after lowering caddy's the axle seems off center. Even though the distance from my spring to the backing plate is exactly the same on both sides, I have noticed this too... Passenger side sticks out 1/2 inch further!




Jacked it back up, loosened the u bolts and slid the beam 1/4 inch to the drivers side. Much better!





And finally .............




I think I got a chubber.


I still have to adjust the front-back since its 1/8" off between the left and right side, then I will weld the plates back on the axle. I ran out of time tonight. I didn't get out there til 9pm and only worked til 11. Considering nothing was even taken off yet(all brakes and everything were still hooked up) I think it was decent progress:D

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Discussion Starter · #30 ·
Thanks! I agree. Couldn't be happier with where it's at.

I kinda look forward to it moving on its own power and parking it next to the Ford for comparison..

Yes. Im a mess and have lots of vehicular interest.
I don't think the caddy is going to handle the mud as well...

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Discussion Starter · #33 ·
Nothing wrong with round eyes!
Although thinking way back in the day on my buddies mk1 gti, on the other caddy I may consider doing Rocco 2 euros. Gives a real chunky look to a mk1.

Welp I found a motor. I hope it runs. Stopped off for the night in Stuart to get a few hours of sleep, then up at 5(I hope) to head down to lake worth to be there by 7 to pick up this 1.6D....:)

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Discussion Starter · #35 ·
Yeah! I think yours is one of the posts I saw. What did you do to flip it? Did you get the shift resolved?(without a 1/2" spacer on one wheel)

Good morning! 4 hours of sleep, let's dtive south an hour and change, go pick up this diesel, then about 4 hours of driving back to the house:D

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Discussion Starter · #37 ·
Well I got the motor in.... in the back pf the dodge lol. Its dirty rusty and ugly but supposedly runs.

I tell you what.. I know there's a mount in the wrecking yard. Make it worth my while to pull it and I will go get it Monday and mail it to you.



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Discussion Starter · #41 ·
Thanks! Me too! What part of town you in? I will see if I can look you up next time I come down.

Just woke up. Long day. On the way back I detoured through orlando and stopped by Triangle ... pair of vented rotors, pads, front and rear wheel bearings, control arm bushings, timing belt roller, and some clutch bits to go with the new disc an pp that came with the truck(pushrod bushing, pushrod seal, input shaft seal, throw out bearing). Then stopped by a naps to pick up a timing belt, oil, filter, and some "engine rebuild in a can" ie spray paint.
Going to cook some dinner and get everything unloaded and figure out what im going to do next this evening

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Discussion Starter · #43 · (Edited)
Damn, what a weekend:confused:

So yeah.. Drove all over creation yesterday between getting the motor, getting parts from one place, then going to NAPA to get the timing belt...
Last night go to get the new belt on so I can drop the motor in today...
FREAKIN NAPA... They gave me a gasser belt.:mad::mad::mad::mad: Boy was I pissed.. Had to drive waaay the hell out of my way to get it after being on the road all day in a dually, and to make it worse it costs almost as much in fuel to return it now since I don't go over to that hell hole area very often. I dont understand how it got screwed up.. Called the location I usually go to, they say they dont have one but Eatonville does.. Go over there, pick it up.. The receipt even says 1.6L diesel.. Part number is even using the OE vw numbers.. So last night I go on Contitech's website and punch the part number in, its for a gasser like I suspected.. Get the diesel number off Autohaus AZ's website, then go back to NAPA's site and look up a belt for a 1.6 diesel, and get the same number as Autohaus AZ's site...
So up til 2am trying to figure out who has one of these bastards in stock, and the closest I can find is the main hub store for Autozone clear down in another sh!thole area in the heart of the Orlando hood, over an hour from the house..
I get to bed about 230, drag myself out of bed by 7 something still tired from the day before and head down to Autozone.. Decided to get a water pump, thermostat, v belt, hoses, etc as well. Ran by Harbor Junk while I was in the 'hood as well to pick up some sh*tty tools. Im sure the 5 pack of wire brushes will fling all the bristles off and lodge them into my leg in the first 30 seconds of use on a cordless drill, but figured they were worth a shot..
Long story short, finally back to the house by like 2pm.. Spend some time with my girl and head out back...

I decided its been long enough since the bead blaster was working, so I finally got my bead blaster operational first.. My dad bought it used for his business in the 90s, and when he closed in like 98 I had him hold it in his garage for me until I got a place I could keep it.. Finally in 2007 I took posession of it, and in 2012 I made it work again.. I wonder why I waited so long...

So, back to the engine.. It looked like royal sh*t when I got it, covered with flaky rust but supposedly a good runner... One thing is for sure, it has hardly any miles on it or it NEVER had the oil changed, or the previous owner was meticulous..Because it had a genuine VW filter on it.. Not even a MANN, but genuine down to the huge VW Audi logo.. I havent seen one of those in a good while..







Today it doesn't look a hell of alot better... I am not sure how long this motor is going to be in there, and I just want it to run... I didnt want to have to fully retime the pump, so I didnt take it off to clean the brackets all that good.. So it got a spray can rebuild, and not a very good one...

After the spray can rebuild, I replaced the timing belt.. I went to replace the water pump, and the second bolt broke off.. Third bolt felt like it was twisting.. Since the clutch looked like new, I figured maybe this thing has had some decent maintance and rather than get into a big can of worms with busted bolts I decided to quit while I was ahead and not worry about the water pump or thermostat. I did replace the rear main on the engine.
I wasnt aware that VW decided not to put ANY timing marks on the pulleys, so I switched gears and pulled the tranny off the engine from the caddy.. Replaced the throw out bearing, pushrod bushing and seal and input shaft seal. Cleaned about 1/4 inch of grime from the bellhousing. Mated the tranny to the motor, and got the timing belt put on and started dressing the motor out..

With the bead blaster running, my girlfriend was cool enough to blast the timing cover, valve cover, intake manifold, AC comp tensioner, and the alt tensioner. Thanks babe!

So TONIGHT, I went to paint those parts.. I cant wait to see the contrast.. Rather than spray bombing the parts that came from the bead blaster, I went ahead did something special...

Also, I am not a fan of clipper kits, but I hate the look of MkI's with absolutely no bumpers.. Since a clipper bumper is all I have laying around, I decided the other day to go ahead and use it until the financial pain of this build dies a bit and I can spring for some chrome euros or find some nice us bumpers to mod..
Since I plan to put the engine in tomorrow evening, and its a royal mother to get the bumper bolts in with the motor in and dressed, it meant I had to paint the bumper tonight... Yay, 9pm and I am fixing to BEGIN prepping the bumper for paint... Wheres the "yawning" emoticon?



Dont worry, it actually looks like hell, LOL... It was chipped and gouged to hell and back... Im partly in a hurry, and dont plan to keep it very long, so I just wanted to make it look better than nothing...


Remember the parts my girl cleaned in the bead blaster? The rest of the engine may look like ass, but some of it wont :)



 
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