Caddy side project

[ottawa coupe]

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

[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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[sal_s2]

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

[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.

[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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[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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[struikie]

Brave stuff!

JW

[Tractor Dave]

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

[K Simmonds]

Looking great Dave as always, you certainly are very thorough and that will show up in the end result.

Have you decided on a colour yet? There's a few 1980's VAG paint's that would suit it well. However my choice would probably be Oak Green, that really is a lovely colour and looks fantastic on car's with proper lines such as MK2's and Caddy's.

[Tractor Dave]

I didn't have the confidence to do the hinge so my friend and neighbour (who is far better at welding than me) came over to give me a hand.



We drilled out the spot welds on both the car and the spare hinge.

Then carefully measured and cut out a section to weld in.



The old hinge was very rusty inside.




I cleaned up inside the bottom of the A pillar whilst I had access and treated some rust at the bottom. Then it got a good hoover and some weld through zinc primer before it was closed up.




The new hinge has tack welded in position and we fitted the door to check its position. We are good.


Then it was a matter of finishing off the welding.



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[Tractor Dave]

I found some more holes.





But I found a good drivers door lower hinge that I can weld in. Happy face!



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[K Simmonds]

That's looking great Dave, Caddy's are never totally rot free, you were really lucky to find such a solid example to start with.

It'll be well worth all the effort you're putting in now, will last for another 40+ years, probably be better than when new.

[Tractor Dave]

Onto the drivers side. After cutting out the rot I found some more holes.



These two are through to the inside.


Anyway, cut it all out and patches made up and weld through primer applied.


A few complicated shapes this side but got there in the end using hammer and dolly. This steel is 1.6mm and not so easy to shape.



I think this section on both sides rusted as water and mud had become trapped inside at the bottom of the sections where they meet. I have left a drain gap at the bottom and will add plenty of good cavity wax inside.
My welding isn't pretty but it's strong.


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[Tractor Dave]

First patch is in.










The other side is a bit worse




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[Tractor Dave]

Got a few more parts cleaned and painted.




And the gearbox got a good scrub.




I'm almost ready to start the few bits of welding required


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