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Old Sckool Vannin

drw42 wrote:Were you in a grey one...with a big smile?

No a white maxi

Really like this

torque777 wrote:Really like this

Thank you mate

the long one wrote: No a white maxi

Thus the long one!! I'll keep an eye out for you Cheers Woody

I had to carpet the inside of the sliding door but had been putting it off as I knew a couple of the rail screws were dubious after changing the rail. I don't know if VW has a proprietary tool for removing the screws but a T25 torx seems just slightly too small and the slightest over torque strips the top out as they are evidently made of cheese in the first place. I had read elsewhere that you should not open the door once the rail is removed as the door falls off. I don't think this is quite true as you need to remove to bits in the top and bottom rails as well. So to proceed remove the rail cover and loosen the rear screws on the rail so you can pull it out past the rubber stop at the end. You then need to remove the rubber bit from the top channel

by undoing the Torx bolt and prising out with a scewdriver. Next remove the bottom stop, two torx this time.
.
The door simply slides back and out. Whilst not overly heavy it helps to have an assistant available to guide and carry if necessary. I then laid it on a soft caravan carpet to protect it from the ground.


The part where the door has been cut back can be seen more clearly here


I then used the old door card to make a new cover incorporating the divot to clear banded steelies.


This was enhanced with a simple cut to fit strip of wood glued and pinned into place. I thought I might need to put a spacer behind it to prevent flexing however in the event it seemed strong enough.

The void was filled with wool insulation
and the cover fitted using the original panel clips (with a couple of new holes drilled along the bottom edge. It was then a simple case of carpeting and cutting off the extra


The door went back on without incident and looks like this closed


I thought the screws holding the rail were going to cause problems. Fortunately I had bought a new set knowing that one at least was knackered and others might also give problems. Having rounded out the torx holes in two of them I was considering where I might find a screw extractor on a Sunday afternoon (if indeed there is such a thing). I had to drill of the top of the screw so I could remove the rail and once I had done so I found it was possible to turn the tiny stub of the drilled screw with a pair of pliers and amazingly they all came out really easily, which is astonishing given how difficult they were to move with the proper tool!!

Whilst the door was off I took the opportunity to try and adjust the release cable to the rear lock mechanism as often you cannot open the door from inside. I am guessing that you might be able to do this from the front but I encountered the same crews as the side rail which were not moving and I did not have enough spare to drill these out as well. I decided to do a similar thing to the rear door where I had fitted an internal pull to release the lock but have yet to complete it.

Having got the door back on I noticed this morning that the door handle seemed loose and did not open. Great!! I am hoping it is just the wool insulation interfering a bit and that I can somehow push it out of the way with a piece of wire. I don't want to have to pull the carpet off and start again.

Love it. Can't wait to see this in the flesh again

drw42 wrote:I don't know if VW has a proprietary tool for removing the screws but a T25 torx seems just slightly too small and the slightest over torque strips the top out.....

Triple square, or XZN - using a Torx will often screw them (in a bad way, not a good way!).

Buy a set - they're all over the place on VAG vehicles (just to make sure you have to buy extra tools!
)

Nice job on the door!

love the window, great seeing someone thinking outside the box and going for something different..

It's nice to see something different. Some good work there mate, I like it!

This vans certainly bringing the retro vibe to the caddy forum! Loving the Port Hole window that's different!!

NZDubNurd wrote: Triple square, or XZN - using a Torx will often screw them (in a bad way, not a good way!).

Buy a set - they're all over the place on VAG vehicles (just to make sure you have to buy extra tools!
)

Nice job on the door!

Thanks Mate, I thought I couldn't be doing it that wrong. Cheers Woody

That is one awesome caddy, love the tan interior I haven't seen another one.....keep it coming