Tube Chassis "VW Caddy" Project

[43655]

Hello all;
Welcome to my project!
It started off as tidying up my '88 VW Caddy, but I got fascinated by motorsport design and engineering at the same kind of time, wanting to ditch the ancient-tech leaf springs for 4-link axle etc, then toyed with a mid engine setup, bought a gearbox and subframe etc from an Audi 80 to suit.

Fast forward a few months, the caddy is now only going to be used as a buck for taking GRP moulds off.
Much to the dismay of the VW Caddy Forum
It will have Audi Quattro-style arches and 'side skirts' to bump it out to 1850mm wide (to match the Ultima GTR)
Mid engine 2.7T V6 mounted to an 01E DQS 6 speed gearbox
I have designed a full tube chassis for the car, as well as plotting front and rear suspension geometry, uprights etc

At the time of writing I'd say the CAD designing side is about 90% there and the chassis fabrication has started
So, photos:








(model is pretty crap, I can't do surface modelling)

This is my first attempt at bot designing and making something of this magnitude.
I welcome criticism and suggestions, as I know there are many much more knowledgeable people on this forum!

[43655]

Some pictures of the actual building

Engine and 'box temporarily mated together

2.7t V6 ARE engine and DQS code 01E fwd box

cutting


Welding


welded


This so far is the lower cab area, and the bottom front wishbone mounting area
I'm using rectangular (50x30x2 mostly) as all these faces will have panels bonded on to increase strength
Final weight for the chassis alone comes out around 110kg, while it's no lightweight it should be stiff and safe

[Hoonigan]

Love it, look forward to watching this progress.

[Megaflow]

Superb. Looking forward to seeing it progress.

[CoolC]

I whole heartedly approve

Looking forward to seeing the progress.

[Steve_D]

I realise your CAD model may be purposely simplistic but worth suggesting that your suspension wishbone include adjustment for caster and camber.

Steve

[dom9]

Subscribed - Looks like a cracking project!

[43655]

thanks guys, much appreciated.
with regards to the wishbones, the front uprights have shim-based camber adjustment, have not yet decided about caster
Was going to just go for somewhere around 8 degrees as a starting point, then if i want to change it make up some new upper wishbones
Seems a bit expensive and time consuming I know, but as i'm planning to use delrin bushes instead of rose joints it's a bit more complicated
maybe I will use rose joints for the UCAs...

[benters]

awesome . .. bookmarked !

[aka_kerrly]

This sounds promising. I signed up to the Caddy forum just to see your thread following the PVW article.

[43655]

...there was a PVW article?

[aka_kerrly]

Hang on a minute, so this isn't the same one that I saw on the Caddyforum? Just how many S4 powered Caddys are there?!

[43655]

ah goodness no, mine is a complete tube chassis, bodywork will be muuch wider than standard.
There are 2 so far that I know of actually.
Really wanted to get into contact with the builder about the emerald ECU he went with, as I may be going down that route.
I hate engine work though so getting the engine running is something i've been avoiding thinking about a bit
Mine currently looks lie this

[aka_kerrly]

I see, I'm looking forward to ok seeing how this will develop!!

[dxg]

Might be too late, but:

http://www.vw-one.co.uk/volkswagen_golf_928.htm

???

[43655]

Interesting, not seen that before. I quite like the wider look next to a standard MK1
What are you suggesting though?

[dxg]

That you could widen the body rather than having the arches. But then you would have to find a windscreen from somewhere...

[43655]

Oh, nah I like arches
The S1 Quattros are one of my biggest inspiration, especially the insane KRB one

But this is to be a road legal car, so plastic windscreen would be out of the question. a custom windscreen would be very expensive!

[43655]

rear end now has the 'suspension box' done, and the main linking tubes


still only mobile phone photos i'm afraid, but have a decent camera on order!

Still not decided on whereabouts to mount the rear suspension yet, and working on designing the uprights still too.
It's getting pretty cold wet and miserable now for working on the chassis, so maybe move onto wishbones and such soon

[GTRCLIVE]

Another guy as nuts as me.... But it is fun doing everything yourself, Caddy V6 DTM stile I like you thinking..... Will be watching this thread.