Caddy side project

[Tractor Dave]

Onto the rust on the windscreen surround.
Repair sections are available and we are cutting one down to fit the rusty bits.





It needs a little more grinding down.


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[Tractor Dave]

After some guidance from my friend, I'm solo on the welding now. Getting the welder set for the thin metal was half the battle.
I've also been following Fitzee's Fabrication on YouTube. He recommends making repair panels on the car before you cut anything out and I have found this very useful. Some excellent advice and guidance in his channel.
Next bit is the rear window. A fiddly spot and also this area has a dent.


Panel had already been shaped before this was cut out.


And welded in.


Ground back and primer


And onto the next bit


Finding just the right thickness card helps



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[K Simmonds]

Thanks Kit.
I've not made a final decision re colour. The car did come with a new 5l tin of the original green so I'm tempted to use that and save a few pounds

5L will easily do the whole thing once thinned down, as long as the can is sealed and the paint still live I'd seriously consider this option as it looks like a nice green anyway and more importantly retain originality. Though that a decision that's entirely up to you, a good mate did his in Helios Blue which is another great colour from that era and looked really nice or there's Lhasa Green which was a very popular MK1 GTI colour, a bit like Oak green just a shade or two lighter.

Nice bodywork BTW, and yes making repair panels before cutting the old metal out make a lot more sense and saves a lot of time.

[sal_s2]

lhasa, dragon, ragusa, oak, mallard (escort cosworth), imperial ( lotus carlton) or classic green (rivage). All great colours

[Tractor Dave]

This is called a side project as it's one I can neglect for a week or two without feeling guilty.
Anyway, after a break I'm back on the welding.
Onto the load area. Unfortunately the company making bed repair sections are out of stock and don't seem to be in a hurry to make any more. I will do my best to patch where possible.


There are a few rust patches.





Here we go. First patches in.



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[ottawa coupe]

Ambitious me says the only sensible answer for the bed rot is a mid engine swap

[Tractor Dave]

Ok, little update.
I wasn't 100% happy with the bed repairs.
To do this properly I needed some repair sections. I had been waiting for some weeks for it to come back in stock with Rectification to no avail. However, it did just come back in stock at VW Heritage so I ordered a sheet.


It wasn't cheap but quality is great and it has made repairing the bed much easier. Now I can get all the welds away from the folds.
We start over again.










Another day or so and the welding will all be done. Smile


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[John.]

Looking good

[Tractor Dave]

The bed repairs are all done.
My welding was slowly improving as I went along. The last couple of sections look quite good.
I had to patch the support rail here.







I have one small repair to do on the rear hatch frame then all the welding is done.


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[Tractor Dave]

At last I got some Novol Protect epoxy on the underside.




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[Tractor Dave]

I did two coats yesterday then flipped the car and did two coats today from the other side.
Engine bay tomorrow.



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[Tractor Dave]

The engine bay took a lot of cleaning. I did it a few months ago and treated the rust but it had started to rust again so I had to re do everything puff puff!


Then everything got de greased


Bilt hydrate 80 then lunch.
Lunch followed by two good coats of Novol epoxy.


Then onto some seam sealing.



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[Tractor Dave]

The nice warm weather is helping progress.
Next step, some underseal.


I've used this before and it gives an OE type finish.


I warmed it up in some hot water.
Goes on lovely.







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[sal_s2]

Ive used that gravitex aswell, good stuff and easy to apply

[Davi123]

Wow that's looking great Dave.