Mk1 Caddy Pickup aka Patches

Got the Tig out and attacked the A pillar.

Please be kind, this is the second time I have tig welded anything propa.

I think I made it hard for my self using 1.6mm filler rod but only a couple blow through's. Stuck a thick piece of brass behind it to sort those areas.

Next it's complete assembly with the gutter section I made. I have seam sealer to fill the gutter rail before sandwiching it with the outer skin. Got to protect all the surfaces with epoxy primer and weld through primer.

At the end I will inject cavity wax to make it better than the factory for belt and braces.

Great job Rich, the boy has skills +++


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Finally got round to welding the A pillar in. Quite a fiddly repair trying to get everything aligned and looking correct. I'm pretty happy with that.

Got the new gutter lip plug welded on:




Then sprayed with Bilt Hamber etchweld. I injected seam sealer in to the folded over gutter and then tucked in the outer pillar. I could use the previous spot weld marks to align the panel to it's original position.



Next on to the windscreen wiper panel and start working back from there  

Yesterday had a look at the other A pillar. The outside surface and gutter looked fine but broke out the endoscope to view the inside and glad I did as rust was hiding  .

Cut the outer gutter off and shot blasted it and then added a treatment for good measures.



Also started making repairs to the windscreen wiper panel. Most of the original panel was salvageable.

Got some more done. Shot blasted the A pillar and welded the outer skin back on:




 

Mocked up the windscreen repair panel and in order to fit the pattern part a10mm fillet needed to be added  .

The panel will need plenty of planishing with a hammer and dolly before welding back on.

Today cleaned the ran tray, removed sound proofing and seam sealer and gave it a coat of epoxy primer.

Looking so so good Rich! Great work!!


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Looking great

Windscreen Repair panel installed and on to the roll over jig next weekend. Should have some revealing photos then!

So we have lift off Caddy is up on the roll over jig and stripped back to a bare shell. The axles have subsequently been removed.

It's not looking too bad under there. The plan was always to replace the complete bed and I already have all the bulkhead repair panels and rear bumper panel.

Managed to tuck the Golf in after I tidied up. Pretty tight as the caddy on the Jig takes up a lot more space.


 

Managed to start on the floor replacement.

Dad and I braced up the shell with 25mm x 3mm box section to make sure everything is rigid.

Then started to open up the floor:

Looks like the inner sill needs some attention where the seat belt mount is and directly beneath the factory jig point it was really rusty.




 

Started to test fit one of the floor panels.

Once all the repairs have been made the floor can be welded in  

Long overdue update on this.

Dad and I have been moving on with the repairs.

Repaired either side of the seat guide.



Created a new inner sill section and used the bead roller to replicate the strengthening impression.



Then the outer bulkhead repair.



Next is the outer sill repair and have a panel for that and finally look to weld the floor section in

Amazing fabrication skills Rich mate! Perfection


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Bit backed up with updates on the Caddy. Whilst the Golf is on ramps I can't get on with the Caddy but dad and I have been busy prior to the winter Golf maintenance.

Re built the inner sill and seat belt mount.