VR6 Caddy Build

[BigSkyVR6Caddy]

VR6 Caddy Build:

I should have started this build thread months ago, but I just figured-out how to post pictures to this site.
Dropping a VR6 into the Caddy should be easy

History: I found an 81 VW pick-up diesel at Brax in Divide.
Body was in good shape and he dropped it off at the house late last summer. Then I found a cheap donor vehicle, 95 Jetta GLX in LA.
Got a cheap one way ticket and drove it back to Bozeman in 21 hours.
Changed plugs, wires, basic tune-up and this VR6 screams... shifts and handles very well.

Project: I want to build a VW pick-up daily driver with LSD necessary power, great handling and a stock clean "83" exterior look.
Must be a comfortable blast to drive.
I will be using the complete MK3 VR6 Subframe system.
I will Modify the Caddy body to accept the Subframe system and have everything bolt-up to the body just like on the MK3.
I will be using as many parts as possible from the MK3 to complete this build.

I started to tear down the pick-up and it then sat like this all winter.

These vehicles are outside and I like to ski too much.
I finally completed the teardown in June and this is what it looks like now.

Nothing left but doors and glass.

Diesel grime is fun stuff to clean!

Almost as much fun as carpet glue!
The floors are luckily very good in this Rabbit.
Only minnor surface rust in a few spots.


This is a good start... I will update again soon.

Alright... I have been prepping the Jetta for VR & subframe removal.

[sneakyboy1]

Looking great man!!
Glad to see you got a build thread started!!
Isn't it awesome how well some of these 25+ y/o VWs hold up against rust?

[bigmontana]

That is so cool a VR plus a caddy, that thing is going to scream. I have always loved the Caddys and still want one. There is a guy in Minnesota that uses them for his business and he has over 25 Caddys and even more in Minneapolis. Plus n assortments of cabbys, golfs and others. And he won't get rid of any of them. He has so many that they are named for their colors or if they have a topper. It is crazy.

Am looking forward to seeing progress pics of your project.

[I B GOLFIN]

Wow that vr is super clean. Props man props

[Rennwagen1]

man, I should have painted the ceter of the rad support on my GTI black the last time I had the grille out..grrrrrrrrr

BTW I love caddys, and I love VR6s, so this thread is pretty much the coolest one on here right now. Sorry to the rest of the Bozo guys, but I still love you too!

[t53a]

cant wait to see that vr stuffed in the caddy. this little sucker should move!

[BigSkyVR6Caddy]

Thanks for all the interest in this build!

The next step was to clean the underbody, remove any rust and paint.
This took weeks with diesel grime and grease seemingly everywhere.

Fuel delivery: I had already removed the diesel gas tank and have decided to use as much of the GLX as possible. I researched and took the direction one of the guys on vwcaddy. He documented pretty well how he converted the existing Caddy tank to hold the guts of the VR plastic tank. First, I unscrewed the big plastic cap and twisted the pump to remove it from the tank. Then I cut-out the base and top of the glx plastic tank for use in mounting to the steel caddy tank.



This is the remaining carcass of the Jetta tank.
Trust me this will start to make sense.

I then cut a hole in the top of the caddy tank the size of the ID of the plastic tank opening, made a big gasket and mounted the top of the plastic tank to the caddy tank with 16 bolts.

Next, I trimmed the bottom piece that secures the pump and cut slits in the plastic that would slip past the baffles in the bottom of the caddy tank. It fit pretty flush to the bottom of the tank and I cut and folded the ends of the baffles to hold this piece in place.
Anybody baffled yet? I know pictures would help, but I was on a roll.

I found a phone pic of the tank after this was completed.



I adjusted the float to bottom-out at the proper level, secured the pump to the base and installed the cap.

I took my time with this mini project and it was worth it... the pump is solidly secure, the gasket worked very well and the Jetta gas gauge will be functional.

The caddy tank is installed. I had to drop it 1.5" for the cap and lines to clear and I brazed a nipple into the fuel neck for the relief valve.

The tank sits nice and looks stock.
It's also big, 15 gallons I think... Later guys!

[Idcorrado]

wow thats gonna be an awsome trick and converting that gas tank is a great idea. GL with the rest of the build. Can't wait to see more. Oh if your looking for anything for the build and can't find it over there let me know and I'll see if I can find it in the my area (Spokane Wa.)

[bigmontana]

Yes good luck, I can't wait to see how this turns out.

[kompressorgolf]

i can see that this will be a very technical build and i look forward to every post of it! and for your good work! MOARRRR