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    Thread: No disasemble Johnny 5 (80' caddy build)

    1. Member hasnfefr's Avatar
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      03-29-2013 11:27 AM #1
      Well, I've had this guy for a touch over a year working on it. I know there are a lot of builds on here, but figured I would share anyway.
      Ad pic from when I bought it.



      For an 80' she was in good shape. Apparently from California.
      Came with a spare 1.8. Some other goodies were installed like rear disk brakes and a close ratio with a taller 5th. Only real rust was around the windshield.



      Last edited by hasnfefr; 03-30-2013 at 12:34 AM.

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    3. Member hasnfefr's Avatar
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      03-29-2013 11:30 AM #2
      First I took out the windshield, removed the interior, and took care of the rust. Blasted it, welded it, light metal finish, epoxy prime and some rattle can paint.





      My buddy Dan got me a windshield and I helped him install it.

      Threatening it with window tint.
      Last edited by hasnfefr; 03-31-2013 at 02:29 PM.

    4. Member hasnfefr's Avatar
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      03-29-2013 11:35 AM #3
      Glad I towed it home. Wouldn't have made it far.



      When we replaced the heater core found these gems.



      At this point I started to get at the motor and resealing stuff, belts, etc.



      I powder coated a bunch of stuff.



      Starting to come together.

      Last edited by hasnfefr; 03-31-2013 at 02:28 PM.

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    6. Member hasnfefr's Avatar
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      03-29-2013 11:41 AM #4
      Well, it was somewhere around this time I got it so it would go down the road safely, and wouldn't ya know it I came across a sweetheart deal on a TDI drivetrain.



      This is about when I lost my god d**n mind

      Re did the tank. It was in awesome shape, but still sealed the inside, blasted off the tiny bit of rust on the outside, epoxy primed, painted, and shutzed.



      Last edited by hasnfefr; 03-29-2013 at 12:05 PM.

    7. Member hasnfefr's Avatar
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      03-29-2013 11:49 AM #5
      Fixed the rust/damage on the front with new metal.




      I was left with no choice to fix the front this way as early westy fronts are not easy to find so I cut up a nos single round and pieced the two together. I just have to do a little body work and all good.

      Fixed up the motor as it came with a specially modified im shaft pulley from a bad timing belt job.




      Fortunately it wasn't so bad. I just replaced the im shaft, pulley, and im bearings. Then on the way out did a proper timing belt job.
      Last edited by hasnfefr; 03-30-2013 at 07:26 PM.

    8. Member wolf_walker's Avatar
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      03-29-2013 11:57 AM #6
      If that IM is on the TDI, pull the crank pulley and check the key on it.

      Good stuff
      https://drivetribe.com/t/WC7s0VaiSNW...SM-mOTDjGESEhA

      One man's garbage is another man person's good un-garbage....

    9. Member hasnfefr's Avatar
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      03-29-2013 12:03 PM #7
      That pulley is tight as hell. I've heard about those having problems as well. Good looking out.

    10. Member hasnfefr's Avatar
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      03-29-2013 12:15 PM #8
      Like I said I lost my mind.


      Motor with bits yellow zinc plated and powdercoated. Just about ready to put in. Have to get to the bay and the rest of the suspension.



      Motor out, time to clean.



      Had to fix a half asses bat mount repair.



      I swore I was just going to clean it up and make it look nice....well like most things, idle hands in the winter and all that.



      Large amount of parts back from plating. Welded control arms, all sorts of neat bits, and surprises.


    11. Member hasnfefr's Avatar
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      03-29-2013 12:21 PM #9
      Here is the bay prior to clear and flake.



      It looks like a 13 year old's nail polish. that's creepy. lol.




      Inner fenders cleaned, converted, primed and shutzed.


    12. Member hasnfefr's Avatar
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      03-29-2013 12:28 PM #10
      On to the back. I really like OSVW stuff. So inspiration comes from him on these items. I'm just to broke to afford it, and fortunate enough to have to the tools to do it. After some steel purchases on line I started to make some parts.





      My buddy helped me out with the plates as he has access to a mill to drill the holes and square them up. He is awesome.




      Lots of mock up. Take apart, put back together, and then back apart again.

    13. Member hasnfefr's Avatar
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      03-29-2013 12:40 PM #11
      I cut down the mounts for the bags a bit.



      Put on the plates for the stub axles.



      My plan is to run both the shocks from the back. So I sourced a factory mount from a salvage yard.


      It turned out to bad to use so I made my own.


    14. Member hasnfefr's Avatar
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      03-29-2013 12:48 PM #12
      For the front I used heim joints with a modified front spring mount and seals it seals for the joints.









      Had to make some bushings and shims. Fortunately I have a small lathe to get into trouble with. The bars that I have on it are for mock up. I'll get something nice later.
      Here is the axle all welded up. Just have to clean it up a bit and send to powder coat.




      Almost forgot the sway bar.

      Last edited by hasnfefr; 03-29-2013 at 01:08 PM.

    15. Member hasnfefr's Avatar
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      03-29-2013 12:59 PM #13
      After starting to bolt some stuff up it made a whole lot more sense to flip the rear brakes around. I don't see any issue with having them this way. This allows me to use mk4 calipers, still have the e-brake cable work, clear the bags (I narrowed the beam a bit), and run the brake lines real nice. At this point I also flipped the bags upside down and ran the lines in the frame rail. This puts the air lines out of harms way and was only a matter of drilling a 1 1/8" hole.



      I also made some delrin bushings for the front control arms and a buffer for the hood latch.




      And powder coated some drop mounts I made.


    16. Member -teknien-'s Avatar
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      03-29-2013 01:01 PM #14
      Quote Originally Posted by g60vw View Post
      If I thought like that I would have gotten out of mk1's back when they were still A1's
      Quote Originally Posted by goosler View Post
      screw all of you & your stupid cars.........see you at madness!
      I'm a 1%er

    17. Member hasnfefr's Avatar
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      03-29-2013 01:02 PM #15
      I have a bunch more pics I will have to upload later.

    18. Member Jesse_717's Avatar
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      03-29-2013 01:04 PM #16
      Impressive. I love an '80 pickup

    19. Member hasnfefr's Avatar
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      03-29-2013 01:13 PM #17
      Axle and new bars back from powder. My oven isn't big enough to do those. Wasn't bad though like $60 for the axle, bars, hood prop, and sway bar.



      You start to see how the sway bar and shocks look in this one.



      More parts from plating.


    20. Member wantacad's Avatar
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      03-29-2013 01:28 PM #18
      cooool
      Quote Originally Posted by WackyWabbitRacer View Post
      You're new here but don't be a DORK.....
      Cheers, WWR.
      Quote Originally Posted by rte7x9 View Post
      Don't swap if you can't weld or fabricate. It's not a trivial task just to bolt everything up. There's a lot of nut-scratching involved. Take your time and do it right.

    21. 03-29-2013 02:08 PM #19
      wow awesome stuff
      https://www.youtube.com/bennyobscene

      Drift Car Build! - now with (V8!) drift car content!

      Benny and the jets - Just your average air cooled 911 adventure

    22. 03-29-2013 02:46 PM #20
      yes
      LE6B

    23. Member rabbitnothopper's Avatar
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      03-29-2013 03:58 PM #21
      plate everything! plate the whole car!!!


      good looking photo job guy

    24. Member oopseyesharted's Avatar
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      03-29-2013 06:59 PM #22
      I am diggin this!!!!
      That rear axle is badass!!!!!

    25. Senior Member Iroczgirl's Avatar
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      03-29-2013 08:34 PM #23
      What a build!! This is going to be show AND go!
      Lots of VW stuff|Rare Scirocco parts!
      The family: 1955 Customline 351C | 1970 TR6 262Olds | 1977 Capri Cologne | 1980 Rabbit AAZ | 1984 C30 350 | 1988 Scirocco 9A | 1988 Scirocco LP7Y | 1992 Pickup 22RE | 1997 D21 KA24E | 2000 Grand Marquis Modular
      Quote Originally Posted by Crimping Is Easy View Post
      You're always better off with a Citroën.™

    26. Member hasnfefr's Avatar
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      03-30-2013 07:05 PM #24
      I got my stainless brake lines back from Classic Tube. Really happy with their fit.



    27. Member hasnfefr's Avatar
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      03-30-2013 07:30 PM #25
      Thanks everyone for the kind words.

      I got a chance to powder coat the headlight buckets. I did them in a single stage almost chrome w/high gloss clear.

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