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 Project Postman Pat

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WizBizMartin
DBS Old Timer
DBS Old Timer
WizBizMartin

Male Number of posts : 2531
Age : 29
Location : W-S-M
My Ride(s) : 85 Mexican Beetle, 20v T Beetle, Honda Xr125
Registration date : 2008-11-27

Project Postman Pat - Page 3 Empty
PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptyMon Dec 20, 2010 11:44 am

mirror polishing ftw afro

looking good coming together !
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Gungemyster
a.k.a. Clunge, The Club Deviant
a.k.a. Clunge, The Club Deviant
Gungemyster

Male Number of posts : 12659
Age : 47
Location : Weston-super-mud
My Ride(s) : 1975 south african imported beetle two tone grey, 1997 Red T4 shag palace
Registration date : 2008-03-28

Project Postman Pat - Page 3 Empty
PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptyMon Dec 20, 2010 1:34 pm

Si your commitment is amazing, it must have been so bloody cold working out there!!

Looking really good fella.
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SimonABT
DBS Old Timer
DBS Old Timer
SimonABT

Male Number of posts : 1343
Age : 37
Location : Clevedon
My Ride(s) : Something with a V6 under the hood!
Registration date : 2006-10-08

Project Postman Pat - Page 3 Empty
PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptyWed Dec 22, 2010 9:09 am

- Nope not running yet.
Havent done anything to her for a week or so. Just cant face the weather.

Mart, yeah i think i will mirror polish the 6 ports at the front of the inlet, and then paint the rest gloss black. (if that makes sense)
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SimonABT
DBS Old Timer
DBS Old Timer
SimonABT

Male Number of posts : 1343
Age : 37
Location : Clevedon
My Ride(s) : Something with a V6 under the hood!
Registration date : 2006-10-08

Project Postman Pat - Page 3 Empty
PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptyTue Dec 28, 2010 5:18 pm

Did a bit more today, fitted the VR6 cable change gear selector, which literally just bolted up onto the exsting mounts, connected it up on the gearbox, then fitted the tunnel heatshield under the car.
Continued sorting out the wiring looms, almost there now.
Very Happy
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nomates
DBS Top Tater
DBS Top Tater
nomates

Male Number of posts : 18609
Age : 46
Location : weston-s-mare
My Ride(s) : 1967 fridolin and 1966 (award winning-and yea i am being gay) ghia and 1960 bubble car
Registration date : 2006-11-19

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PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptyTue Dec 28, 2010 7:07 pm

good news , bet your glad the weather has got a tad warmer ......I know I am
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SimonABT
DBS Old Timer
DBS Old Timer
SimonABT

Male Number of posts : 1343
Age : 37
Location : Clevedon
My Ride(s) : Something with a V6 under the hood!
Registration date : 2006-10-08

Project Postman Pat - Page 3 Empty
PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptyTue Dec 28, 2010 7:24 pm

nomates wrote:
good news , bet your glad the weather has got a tad warmer ......I know I am

Hell yeah. Although ive heard its supposed to be getting bad again later in the week? Sad
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nomates
DBS Top Tater
DBS Top Tater
nomates

Male Number of posts : 18609
Age : 46
Location : weston-s-mare
My Ride(s) : 1967 fridolin and 1966 (award winning-and yea i am being gay) ghia and 1960 bubble car
Registration date : 2006-11-19

Project Postman Pat - Page 3 Empty
PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptyTue Dec 28, 2010 7:29 pm

well ....its a credit to you .....at first i had no interest in your projects ,being watercooled an all .....but reading your resto's what you do is actually a lot braver than just tackling rust and body work ,its very technical .......and I have'nt seen a caddy as good as your old one ,ever! .......i know this postman pat mobile will kick some ass ,your a top petrol head in my book dude ........keep it up Very Happy
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vwbeetlebum
DBS Top Sphincter
DBS Top Sphincter
vwbeetlebum

Male Number of posts : 6572
Age : 104
My Ride(s) : Your Mum
Registration date : 2006-08-19

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PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptyTue Dec 28, 2010 8:33 pm

yep as above, very talented
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SimonABT
DBS Old Timer
DBS Old Timer
SimonABT

Male Number of posts : 1343
Age : 37
Location : Clevedon
My Ride(s) : Something with a V6 under the hood!
Registration date : 2006-10-08

Project Postman Pat - Page 3 Empty
PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptyWed Dec 29, 2010 3:54 pm

Ha cheers fellas. Although the last Caddy was 80% help from my old man. Couldnt of done it without him. He's tought me so much since i started playing with cars.

Glad your not getting bored of the build threads. lol
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SimonABT
DBS Old Timer
DBS Old Timer
SimonABT

Male Number of posts : 1343
Age : 37
Location : Clevedon
My Ride(s) : Something with a V6 under the hood!
Registration date : 2006-10-08

Project Postman Pat - Page 3 Empty
PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptySun Jan 09, 2011 9:27 pm

Did a little bit more this weekend inbetween working on the house...

Stripped out the back of the van to gain access to the fuel tank to fit a fuel pump.
You can also see in the pic below that fitting a rear bench seat from another car would be easy as the caddy already has the steel base frame.

Project Postman Pat - Page 3 168981_478620142722_552862722_6475209_1780655_n

As the Caddy was originally diesel it never used an elec fuel pump, i tried the Mk3 VR6 fuel pump (sits inside the fuel tank) but it didnt sit properly, so i asked my cousin (maltloaf on here) if i could pinch the mk4 Golf 1.8T fuel pump from him as he is currently doing an 1.8T swap in his mk2 golf.

As luck would have it the mk4 pump fitted perfectly Very Happy

I now need to run a new loom from the fuse box to the pump in order to get the pump working.

Pic of fuel pump sat inside Caddy tank -

Project Postman Pat - Page 3 168981_478620147722_552862722_6475210_7265824_n

I have also been on the look out for some cheap 5x100 Steels or Alloys as i hate the standard VR6 BBS alloys. When a mate of mine said i could have his set of 4 Audi TT wheels for an absolute bargain with 4 new tyres! Im not so sure if they suit the caddy, think they look a bit too big, but they were cheap and i thought i'd take a gamble.
Hopefully they will look better once the van is lowered on the back and i can wind the front coilovers down a bit more.

Project Postman Pat - Page 3 168981_478620127722_552862722_6475206_6594801_n
Project Postman Pat - Page 3 168981_478620132722_552862722_6475207_2184794_n

Thats it for the moment, hopefully this week i should have time to sort the fuel out, connect a few things and fire her up.
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WizBizMartin
DBS Old Timer
DBS Old Timer
WizBizMartin

Male Number of posts : 2531
Age : 29
Location : W-S-M
My Ride(s) : 85 Mexican Beetle, 20v T Beetle, Honda Xr125
Registration date : 2008-11-27

Project Postman Pat - Page 3 Empty
PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptySun Jan 09, 2011 10:25 pm

i think those wheels look prety dam cool bud ! lowered a bit more of course !
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SimonABT
DBS Old Timer
DBS Old Timer
SimonABT

Male Number of posts : 1343
Age : 37
Location : Clevedon
My Ride(s) : Something with a V6 under the hood!
Registration date : 2006-10-08

Project Postman Pat - Page 3 Empty
PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptyMon Jan 10, 2011 8:22 am

WizBizMartin wrote:
i think those wheels look prety dam cool bud ! lowered a bit more of course !

Cheers Mart, yeah once the rear axle is flipped i can then wind the fronts down to give it a nose down stance
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SimonABT
DBS Old Timer
DBS Old Timer
SimonABT

Male Number of posts : 1343
Age : 37
Location : Clevedon
My Ride(s) : Something with a V6 under the hood!
Registration date : 2006-10-08

Project Postman Pat - Page 3 Empty
PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptySun Jan 16, 2011 5:53 pm

ITS ALIVE! Very Happy

Had a few hours spare this weekend, so i made up a new loom to go from the fuse box to the fuel pump, 2 wires for gauge, and 2 wires for power and earth.
Also connected up a few more wires in the fusebox area, swapped over the relays needed for the vr engine loom.

Decided i would connect battery up and turn ignition on to see if fuel gauge worked, to my suprise the fuel pump primed.... so i thought hmm sod it i would just try and start it, after all it would either short something out and not run, or it would try and start up.
To my amazment it fired up 1st turn on the key, no misfires, no rattles, no tapping, just a sweet sounding VR roar. I was over the moon!
bounce

So now the game is on to build it back up.
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WizBizMartin
DBS Old Timer
DBS Old Timer
WizBizMartin

Male Number of posts : 2531
Age : 29
Location : W-S-M
My Ride(s) : 85 Mexican Beetle, 20v T Beetle, Honda Xr125
Registration date : 2008-11-27

Project Postman Pat - Page 3 Empty
PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptySun Jan 16, 2011 6:18 pm

good man ! all about a video or at least a recording of the VR sound ! :p
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Shamrockez
DBS Old Timer
DBS Old Timer
Shamrockez

Female Number of posts : 2047
Age : 35
Location : Curry Rivel, Somerset
My Ride(s) : 98 New Beetle, 1958 Bug, 1966 Split, 2006 T5, 71 Bug, 72 Bay and 61 Split.
Registration date : 2006-11-21

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PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptySun Jan 16, 2011 8:14 pm

Yeah, video would be good! Very Happy


Bet it must be nice to hear it fire up with no issues.
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http://www.evvo.co.uk
SimonABT
DBS Old Timer
DBS Old Timer
SimonABT

Male Number of posts : 1343
Age : 37
Location : Clevedon
My Ride(s) : Something with a V6 under the hood!
Registration date : 2006-10-08

Project Postman Pat - Page 3 Empty
PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptySun Jan 16, 2011 8:24 pm

Yeah i was amazed there were no issues. Its LOUD as i have no exhaust on it at the moment. lol
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nomates
DBS Top Tater
DBS Top Tater
nomates

Male Number of posts : 18609
Age : 46
Location : weston-s-mare
My Ride(s) : 1967 fridolin and 1966 (award winning-and yea i am being gay) ghia and 1960 bubble car
Registration date : 2006-11-19

Project Postman Pat - Page 3 Empty
PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptySun Jan 16, 2011 9:54 pm

afro
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Gungemyster
a.k.a. Clunge, The Club Deviant
a.k.a. Clunge, The Club Deviant
Gungemyster

Male Number of posts : 12659
Age : 47
Location : Weston-super-mud
My Ride(s) : 1975 south african imported beetle two tone grey, 1997 Red T4 shag palace
Registration date : 2008-03-28

Project Postman Pat - Page 3 Empty
PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptySun Jan 16, 2011 11:35 pm

Nice one Si, awesome work. Cant wait to see it.
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HRD
DBS Old Timer
DBS Old Timer
HRD

Male Number of posts : 1507
Age : 41
Location : Bridgwater!!!!!!
My Ride(s) : Too many to list!
Registration date : 2009-05-04

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PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptyMon Jan 17, 2011 10:08 am

good work mate, nice one!!
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tango_van
DBS Old Timer
DBS Old Timer
tango_van

Male Number of posts : 2846
Age : 38
Location : Wsm
My Ride(s) : 1972 Westy Camper Van, 09 Newbie 1.9tdi, Audi A4 B7 S-line
Registration date : 2006-10-11

Project Postman Pat - Page 3 Empty
PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptyMon Jan 17, 2011 8:06 pm

What exhaust you gonna fit on it and have you sorted the bonnet clearance yet, or is it gonna be stepped up to get more air in?
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SimonABT
DBS Old Timer
DBS Old Timer
SimonABT

Male Number of posts : 1343
Age : 37
Location : Clevedon
My Ride(s) : Something with a V6 under the hood!
Registration date : 2006-10-08

Project Postman Pat - Page 3 Empty
PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptyMon Jan 17, 2011 9:17 pm

tango_van wrote:
What exhaust you gonna fit on it and have you sorted the bonnet clearance yet, or is it gonna be stepped up to get more air in?

Going to be using the standard VR6 exhaust from manifold, to centre section (including CAT). Then custom make the rear section with a 2.5" single pipe out back. Nothing too major, and made out of steel, not stainless as ive never believed the hype about stainless exhausts. A decent heavy duty steel will last just as long as a crap 'stainless'.

Havent even looked at the bonnet issue yet, think im just gonna stamp on it Laughing
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tango_van
DBS Old Timer
DBS Old Timer
tango_van

Male Number of posts : 2846
Age : 38
Location : Wsm
My Ride(s) : 1972 Westy Camper Van, 09 Newbie 1.9tdi, Audi A4 B7 S-line
Registration date : 2006-10-11

Project Postman Pat - Page 3 Empty
PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptyMon Jan 17, 2011 9:42 pm

SimonABT wrote:
Havent even looked at the bonnet issue yet, think im just gonna stamp on it Laughing

'Power Bulge' Twisted Evil
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SimonABT
DBS Old Timer
DBS Old Timer
SimonABT

Male Number of posts : 1343
Age : 37
Location : Clevedon
My Ride(s) : Something with a V6 under the hood!
Registration date : 2006-10-08

Project Postman Pat - Page 3 Empty
PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptyMon Jan 17, 2011 9:50 pm

I may have to try and do something with the engine mounts aswell, when i revved the engine there is quite a bit of movement which i think may cause issues. When i built the Mk2 VR i cut down the rubber mounts by 2", may have to do the same with the caddy too
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SimonABT
DBS Old Timer
DBS Old Timer
SimonABT

Male Number of posts : 1343
Age : 37
Location : Clevedon
My Ride(s) : Something with a V6 under the hood!
Registration date : 2006-10-08

Project Postman Pat - Page 3 Empty
PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptySun Jan 30, 2011 3:38 pm

I have been on the look out for a decent front bumper and headlights for the caddy as the previous ones were badly damaged. And i stumbled across a thread on the caddy forum on 'how to fit a mk3 ibiza frontend'. I think the mk3 Ibiza Cupra R front looks absolutely awesome but when i looked into the cost of parts it scared me a little.
I would need the front panel, bumper, headlights, wings, bonnet, grill, front spoiler, indicators, and scuttle panel, and the cheapest parts i could find were £400+. Shocked

So i sourced a Mk2 Ibiza GTI Cupra instead, managed to find one at a bargain price of £80 for the front panel, bumper, grill, spoiler, foglights, headlights and clear indicators. The Mk2 ibiza shares the same front wings and bonnet as the caddy so it was all a bolt on job. As an added bonus (which i only found out after i trial fitted it) the Corrado VR6 radiator is the same length as an ibiza GTI radiator, i happened to have a corrado one hidden away in my unit so fitted that in place on the Ibiza front panel perfectly. Very Happy

The only modification i had to make to get the front end on was trim the front panel to clear the inlet manifold and dipstick.

Measured and marked out where i needed to cut...

Project Postman Pat - Page 3 164512_488190882722_552862722_6613026_3308968_n

Trial fitted...

Project Postman Pat - Page 3 165331_488190707722_552862722_6613017_5561927_n
Project Postman Pat - Page 3 163707_488188287722_552862722_6612986_8202806_n

I will have to fit some rubber edging of something where ive cut as its pretty sharp even after i filed it.

And with the Ibiza frontend trial fitted on...

Project Postman Pat - Page 3 166442_488191027722_552862722_6613027_7008601_n

Oh yeah i forgot, in order to use the Corrado VR6 radiator i needed to modify the power steering pipe that runs along the front cross member as it fouled the bottom rad pipe..

Project Postman Pat - Page 3 180481_488200982722_552862722_6613255_2340290_n

to this....

Project Postman Pat - Page 3 164791_488201012722_552862722_6613256_5145936_n

Job done! Cool
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SimonABT
DBS Old Timer
DBS Old Timer
SimonABT

Male Number of posts : 1343
Age : 37
Location : Clevedon
My Ride(s) : Something with a V6 under the hood!
Registration date : 2006-10-08

Project Postman Pat - Page 3 Empty
PostSubject: Re: Project Postman Pat   Project Postman Pat - Page 3 EmptySun Jan 30, 2011 3:57 pm

Next job is to source some Corrado VR6 Twin fans, or get a decent size slim line motorsport fan, then got to make up an exhaust. Woooo not long now!

Then its onto the bodywork Sad
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