Covid caddy project

[fishynos72]

Hello All,

Back at it rebuilding the van post accident.



I have a 99% complete vehicle again,



Not sure I like the guard being a different colour, but I'm hoping it's not for too long.

Unfortunately most of my 'paint funds' have gone into simply getting the van back together.

I finally had the chance to install my siderail cover kit from Darkside,





I'm now also running their EGR value delete.



Given I'll have to re-gas the Air Conditioning system post accident, I took the opportunity to retire the 300,000km old compressor and very worn condenser.



The early mk3 style is no longer sold, and the shorter mk4 version replaces it, meaning someone else doing a frond end swap wont have to clearance their radiator support panel like I originally did.


I will eventually replace my radiator support panel as it was damaged in the accident, and I don't like the repair or the now redundant clearance work being so visible.

My front brake callipers came back from Zinc plating, and all went back together well.




Each corner has new flexible lines too



My caddy life (Touran) armrest is finally complete as my replacement rear vents arrived.



These are very difficult to get locally. Id really love the ratcheting Touran style, maybe one day.

I'm stuck waiting for my rear brake callipers to be finished, so unfortunately the van still isn't drivable.

Though in better news, I have finally sorted my panel gaps to a point I'm happy with them


Once I have my rear brake callipers I will have a video update of the work carried out.

[Lister79]

Sorry to hear that, some people are absolute Kn@@‘s, so frustrating.

Good to see you’re putting it back together.


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[Lukie786]

Love those seats bud

[fishynos72]

@Lister79 Thanks, It's not ideal but I'm too far down the rabbit hole to quit now.

Locally there's a loophole in 'write off' laws due to the age of my van so I am lucky in that respect.


Just got word my rear calipers are ready for collection- Aiming to be on the road Monday afternoon.

@Lukie786

Thanks they were originally the 'daily seats' out of my golf. So I already had them kicking around.
I'm thinking of swapping them for something different soon

[fishynos72]

Made good progress today

Van is driving and in need of a wheel alignment and an AC re gas.
But we're back baby!!

https://youtu.be/bDp7OoyU_Fo

[Simon_B]

Sorry to hear about your accident.

Loving the cleanliness of this build, Top effort mate.

[fishynos72]

Sorry to hear about your accident.

Loving the cleanliness of this build, Top effort mate.

Thank you.

Inspired by your build I've purchased mk7 brushed chrome inside door handes

Curious how you got them out of their housing to swap into the caddy door cards?

Decided to freshen up the plain door cards with alcantara and mk7 golf door handles.

Also trimmed mirror covers, awaiting my life mirrors to turn up before refitting.

[BenXCIV]

I had to destroy the handle surround on the donor mk7 door card, so that I could get the silver handle & the locating pin out in one piece.
Then I cut through the locating pin on my mk4 door card, so the black handle could come out freely.

Maybe there's a cleaner way of doing it

[Simon_B]

Hi

I removed the door card inserts first as was retrimming them. I lightly sprayed some wd40 around the pin/spring then used a flat blade screw driver to 'pop' the pin downwards then used long nose angled pliers to 'push pull' the plastic pin out.

Similar process to refit, just tidied up the pin with a nail file to make refitting easier.

[fishynos72]

@Simon_B


Ta for that, I'll give that a crack tomorrow night.
Have a sirocco mirror switch, and golf 7.5 window switches to go into the door cards too.
I will be trimming the inserts hopefully Jan too, but might leave that to a professional.

[fishynos72]

Well we’re finally out about and daily driving again. Few new noises since the accident, still working through those.

Threw a bunch of stuff at the car finally last night.
Mk8 golf window switches- small chrome tips, updated logo and white illumination.
Still need to re-pin to suit, but it’s the introduction of a theme.
Scirocco folding mirror switch to go with my caddy life mirror set (Unfortunately it’s not white illuminated- Looking into having someone convert some items for me from the red.), and still need to source the correct door modules to suit the folding function, but I’ve modified the mounting and the wiring to suit everything else mk3 spec.
I then went to war with the interior door handles, and have successfully managed one side, but I’m questioning if the effort is worth the result.
(INSERT PHOTOS HERE).
To complete the facelift of the van I’m in the process of going from the old mk3 intake

To a more modern 2019 mk4 TDI spec setup.


This images shows the difference in shape. This is a slight issue.


As you can see below

So I will attempt to alter the shame to clear the radiator fitting.

Fingers crossed.

[Marcotdi]

What have you used to paint the plastics? Spray can? Brush? Any specific brand or product? Never tought of doing this but they look so good

[fishynos72]

Small update.

I now have much of the airbox sorted for now.



The before shot.



After



Just need an engine cover logo and a tidy up.

Also got my folding caddy life mirrors on the car.

Just need to sort out the correct door modules to enable the folding action



Finished off with a well overdue wash.



Really need to win lotto and get this thing all one color

[horace01]

Glad it's back on the road.

Please tell my you reported the uninsured unlicensed driver to the cops?

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[fishynos72]

@horace01

Police attended due to the unlicensed driver being unable to produce any form of ID, the vehicle he was driving was still registered in the last owners name too.

The whole thing was a slow motion nightmare, insurance didn't know how to handle the case as the vehicle was being repaired by me and because the driver at fault was unlicensed.
In the end, there unfortunately was no justice or satisfaction.

Karma will hopefully sort it all out.

Ironically less than a week after it was back driving, while parked a multivan backed into the front of the caddy.
Thankfully it only broke the number plate cover and the driver was kind enough to leave details.