mk1 golf caddy/homemade 24v v6 4wd turbo

[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

[powernut]

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

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,,,

[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

right guys due to priming the bug etc ,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

[powernut]

grind ed it up


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

i hope theres enoegh pics for u ...:thumbs_up
unsure how close it will be to the front ,as i just gessed,,,

[powernut]

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

[powernut]

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

[powernut]

decided to use differnert type of ht leads


and polished rocker as well tidys things a little

[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

,
started building engine engine back up 2day ,as i thought chuff the head spacers ,get the lathe out and skim em lol

[powernut]

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



therd some bolts and bit of welding for the flange

[powernut]

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,,

[powernut]

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


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

[powernut]

hi all not to mutch happerning at the mo ,,,but ive a little update ,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

[powernut]

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

[powernut]

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 ,,,

[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 ,

[powernut]

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,,,

[powernut]

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

[powernut]

engine comeing along nicely now ,,,



soon be ,,caddy moding time ...carnt wait ,,,lol like a kid in a sweet shop
had a spare hour 2day so modifyed the from wheels,suspension, couldnt see point of useing mk4 subframe after some further thing,wishbones,to fit 5stud ,not my ideal choice of alloy but they will have to do at mo , ,least the big discs should stop a little better then the std 4stud jobys




sorted another homemade mody ,fit central and pimped lmao

[powernut]

trail fit the engine 2day ,as i reckon it will fit fine ,evern with the 6speed as i thought i was going to butcher the inner wings out ,,some things will be a bit tight but i aint going to worry about them ,,my home made turbo fitsand has lots of room ,still ill have re locat the extrenal wastegate


just made a start on the short runner

bit of bending here and there ,and it will fit ,

i reckon ill get a radiator and fan thown in there
may have to find another place for the intercooler

[powernut]

few more bits done and started 2day

welded pipes on short runner


,i need to angle it more ,ill sort this no probs

trail fit of the propshaft
those garden bricks come handy lol

riped the old rear axle off, and oh dear dam std golf is short as well ,what a suprize

then thought ill trail fit the rear 4motion axle ,and yes,,more stress ,i shorted it too mutch ,as i only tuck a outside measurement of the tyres ,forgot about the thickness ,,lol


as u see from the rear wheel,looks ok thow ,so recut and welded a bit more on ,
seems better