Our 2011 Ex BG Caddy Camper Build

[Gabbus95]

Wasson! Me and the mrs got this Caddy with 126k off a good family friend back in January, who had it for 3 years previous to us, we was originally going to get something bigger, with intentions to do a build, but this came up and it was not at a bad price either, so i managed to knock the price abit as body work isn’t all great in places(no rust, just scuffs n dings) and no service / work history. Although i know some bits had already been done such as the clutch, despite there being no paperwork, there was still more work it needed! £3350 and fresh MOT and it was ours!


First thing to sort was Cambelt & Water pump, some wishbones, full service and then injector seals as there was oil all in the rocker cover. I was already aware of injector issues with these but looking at the injectors it seemed like 1&2 had already been done. Leaving me with 3&4 to go if they ever did. So it went to the garage and they started changing the seals, but injector 3 was not budging at all they didn’t want to get involved and told me to go to a specialist. So it was handed back to me, but before i seeked specialist help i wanted to try the ATF mixed with Acetone trick, so i doused the injectors with this mix numurous times over a couple days and loosened the clamp ever so slightly on the last day and ran the engine up to temp, before you know it we had movement/chuffin on injector 3, so doused it again, clamped it and back it went to get all new seals back on, and no oil on the rocker, ideal. With that 2 weeks later injector 3 gave in so got that replaced and it obviously took a hiding during extraction and a was probably weak/on it’s way out anyways. Engine wise, that’s where i’m at currently, the rest of the build to is follow, got lots of photos, cheers


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[Gabbus95]

Vans running sweet, so far

So inbetween all of that, i have been getting on with gutting the back of all it’s panels and trims etc. Also removed bulkhead and passengers side seat. Now getting ready for sound deadening, recycled plastic bottle insulation, running some cables and vapour barrier, after a good clean and wipe down.






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[Gabbus95]

Sound deadening in every outer panel skin i could see/ physically reach, once that one done got on to the insulation and also go that in every place i could! Then after i tapped any holes over with aluminium tape.







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[Doc]

That's got the making of a very comfortable caddy the way you are going with it. Keep up the good work.

[Gabbus95]

You may have also noticed I now have the 2 sliding door windows and 2 rear quater windows installed. Bit of a fiasco with these, i was originally going to do this myself but i got recommended someone locally who has done work for people i know and was talked into it just to save me a job and have come backs if anything went wrong and all of that, so i thought fair enough and went ahead with it so it could come back and be done and i can carry on! Anyways i get it done, vans come back and the two sliding door windows i’m not happy with or just can’t take my eyes off.. drivers side is sat higher than the rear quater window it meets, and the passenger side the bottom of the window is poking out about the thickness of the glass.. this one bugged me more as i could see the step in the window joins in the wing mirror a week later it goes back to the fitter, said he needs to wait for the window adhesive to harden before removing and re-fitting, fair enough. Anyways i take it back, hoping he can atleast sort that, hour later i get the call to say it’s done and he’s out on another job at this time so has left the keys with someone, told me where to etc.. So i get the van and absolutely nothing has changed, there was definitely no window removal, if anything it was pushed in more about mm or two, he’s just tried to heatgun it in and held it with scotch tape or something so i was kind of done with this guy with his work ethic and attitude towards this and took it upon myself to remove both sliding windows and re install them myself. So with abit of a sweaty removal and a smooth re-install, i had the windows in and where i was happy with. It took a little brute force mind, to flex the glass and get them in tight but it’s sorted and i’m more than happy with my results, been on months now and have no leaks either pictures to follow!









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[Gabbus95]

That's got the making of a very comfortable caddy the way you are going with it. Keep up the good work.

Thank you, I appreciate it! It’s really coming along now, photo’s up soon


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[Dixieland]

Cracking start so far mate.....hope you get as much pleasure out of it once it's done as i'm having with mine

Can't believe VW got away without a recall on the injector carry-on. I had exactly the same with my 2013 when i got it last year and decided to replaced all 4 and carry a couple of the used good ones in the van as it's always in the back of your mind that they will fail again..........plus AA cover so hopefully if/when it happens again i should be able to get going fingers crossed.

Looking forward to seeing more progress

[Gabbus95]

Cracking start so far mate.....hope you get as much pleasure out of it once it's done as i'm having with mine

Can't believe VW got away without a recall on the injector carry-on. I had exactly the same with my 2013 when i got it last year and decided to replaced all 4 and carry a couple of the used good ones in the van as it's always in the back of your mind that they will fail again..........plus AA cover so hopefully if/when it happens again i should be able to get going fingers crossed.

Looking forward to seeing more progress

Cheers mate! I’m sure i will, even just driving it how it is now is joy, minus the injector cloud that looms over you but at least we are aware of it but the days away in it will be even better and well worth. And yeah that’s pretty poor from VW, 2.0tdis would’ve been the one to have in the vans! And yes i need to get involved in the AA cover aswell… cheers bud


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[Gabbus95]

Running cables for split charge, electric hook up, solar panel, leisure battery, all being contained down underneath the passenger seat. Aswell as a couple cables from the middle of the van and then from the middle to the back. Also made the electric board and some battery retaining brackets, welding chain link to angle to run a strap through. Excuse excessive fuse box but just going with it.








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[Gabbus95]

Up on the roof now! Got rid of the old antennas and wiring. Used the rubber washers off the antennas’s on the top side with some dome headed bolts. And on the underside, a nut, washer and another rubber washer with a whole load of sika/sealant, both sides, sandwhiched, should hopefully keep it dry!
Next up was to fit the flexi 110w solar panel, drill a hole for the cables and run it all through a gland which was also stuck down and sealed
Lastly, the roof bars which i thought would be a quick and easy fit, but i was so wrong, had my whole body weight to bring the ends down just so bolt could reach the thread anyways got there in the end and it’s looking good!






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[Gabbus95]

Got the celotex in and stuck on, inbetween the battons, little bit of expanding foam to fill any gaps aswell.
As you may have noticed in this first photo, you can see spray adhesive from a failed attempt from carpeting this was emotional and am in no rush to do carpeting like this again uness it’s straight panels anyways i took on the task and i am happy with the results, patience is key and doing little bits at a time… passenger side, being the first, success on 3rd attempt and the drivers side was done in the first go thankfully, obvs got the hang of it, there certianly is an art to it but there is with most things! Barn doors also done, found them tricky too but we got there.. and left the easy bit till last, the door cards/panel cut outs. Nice to get this in











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[stu_b]

You've done yourself proud
Looks like a LOT of effort gone into it
The results speak for themselves

Btw what colour is the 4 way ?

[Gabbus95]

You've done yourself proud
Looks like a LOT of effort gone into it
The results speak for themselves

Btw what colour is the 4 way ?

Thank you mate i really appreciate that! And it’s listed as Barley on ebay, it’s a strange one, i was abit unsure at first but it’s grown on me


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[Gabbus95]

I removed the blackout film on the rear barn doors and then got them tinted, so i could see out the back. I also went for a sunstrip, that darkens the cab a fair abit which is nice, i fully recommend if your cab feels abit open and bright!
I also got some Heko wind deflectors and fitted some smoked side repeaters.. although i think i might be got down the mk4 side repeater route soon as they are a much better shape/style!







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[Gabbus95]

Door rubbers back on after carpeting, that tidy’s it up, hiding those cut edges! I’ve also done the bulkhead chop and kept the bits that cover the sliding door recess and also carpeted them.

Onto the ceiling next, i used 8mm T&G with a nail gun and some stixall, inbetween this i have fitted some ebay special 12v remote control dimmable warm white LED’s.

Then it was time to get to the floor, so i gave that a good clean and hoover and then got 6 sound deadening mats stuck down, vapour barrier on top of that then it was time to get the ply in!











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