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Basically I used a heat gun to warm the plastic at the back corner where my tyres catch and then used the wooden handle of a rubber mallet to stretch the heated plastic, held it for a minute or so until it cooled down enough to hold the new shape. Where it wasn't successful was it didn't hold the new shape as well when I moved to a different part and so added heat again - the bit I'd just stretched shrunk back slightly. My plan going forward is as you say, split the arch and add a new piece by plastic stapling and welding. That should work better in the long run although I couldn't hear it catching on my test drive.

The other part was the top most section where it joins the arch lip. It has a slightly bulbous shape which means my tyres would push against it when I was fully aired out and as it turns out, were preventing it going lower. Having cut off the section (see below. The one on the top looks bad because I had been heating it and bending it but I realised it wasn't working so cut it off) I now need to come up with a solution but that is going to be tricky. I know quite a few low caddy's have done this or removed the liners, but I'd like to keep them as much as possible.



I've had my arches rolled on a MKIV R32 using the method you describe. Done carefully you can gain quite a bit of clearance.

Have you looked at the part numbers on your arch liners? There are a wider type for vehicles supplied with 16" wheels, I'm wondering if they'd be any better if that's not what you've got already.

Mine should have been the wider ones already as it had 16” wheels but I’ll double check anyway.

I have the wider ones and with airride under the van the innerarches are already partly eaten away by the tires, will get them out and 2 3 layers of body shoot in the arches like I did before when I drove with 10J rears under my facelift van. have the wider rear axle and the wider inner arches.

The blue... Dan... when it's sunny it's a great effect in that color of Audi.

dan@biali wrote:Have you only read the first couple of pages?! KW kit is long gone and the BBS wheels are now my winter or servicing set. Have a look at the last couple of pages to see what it looks like now!

Just missed a few years worth of mods


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Amazing build Dan

loved reading the 110 pages .

This is something else. Completely next level.
Amazing work! At least this gives me something to aim for!

Stunning van and good read

What a transformation that caddy looks stunning


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@dan@biali Do you remember what color/code the alcantara you've used is please?

No sorry I don’t. I think it’s called anthracite but I’ll see if it’s listed on my invoice.

No worries, thanks

Checked my invoice, its just described as charcoal alcantara. I know its the really expensive version so will be the best quality brand but no idea who that would be.

Nice one, ordered a 'Alcantara Charcoal 6422' sample from AS-trim, hopefully it's genuine stuff

excellent build makes me wish i had moor time and funds to be able to do some of these mods keep up the great work