VW Transporter Day Van Conversion
Discussion
Mirror covers are on, bumpers will wait until I've tided a few other bits up first.
Started stripping both front corners. Picture of the nearside, which in theory should be in the worst condition.
Other than being filthy it's pretty much immaculate. The sum total of the corrosion can be seen here.
The strut came out relatively easily, plenty of penetrating oil helped.
Found some glass under the scuttle panel so I assume it's had a new windscreen at some point. Probably quite difficult to see in the picture. You can see the strut top down in the recess.
Light stopped play with both corners stripped down. Shouldn't be too much drama refitting but will tidy parts up as they go back on.
Started stripping both front corners. Picture of the nearside, which in theory should be in the worst condition.
Other than being filthy it's pretty much immaculate. The sum total of the corrosion can be seen here.
The strut came out relatively easily, plenty of penetrating oil helped.
Found some glass under the scuttle panel so I assume it's had a new windscreen at some point. Probably quite difficult to see in the picture. You can see the strut top down in the recess.
Light stopped play with both corners stripped down. Shouldn't be too much drama refitting but will tidy parts up as they go back on.
ChocolateFrog said:
AyBee said:
What's the best engine for these? My parents have a Caravelle with the 274bhp 2.5TDi which goes well, but all the commercial vans seem to have the 1.9TDi lump - is it any good?
The pre facelift vans have either the 1.9 with 84bhp or 102bhp (mine has this), or the 2.5 with 130bhp or 174bhp. The 1.9 is fine, and can be remapped to 130hp if that's your thing, and while not quick, it does the job. The 2.5 5 cylinder sounds a lot nicer, produces more power, but can be very expensive to fix if it goes wrong. Post facelifts come with a 2.0 in either 84, 105, 140 or 180bhp flavours. The 180 is a bi-turbo and by all accounts can be troublesome. LeighW said:
ChocolateFrog said:
LeighW said:
The pre facelift vans have either the 1.9 with 84bhp or 102bhp (mine has this), or the 2.5 with 130bhp or 174bhp. The 1.9 is fine, and can be remapped to 130hp if that's your thing, and while not quick, it does the job. The 2.5 5 cylinder sounds a lot nicer, produces more power, but can be very expensive to fix if it goes wrong. Post facelifts come with a 2.0 in either 84, 105, 140 or 180bhp flavours. The 180 is a bi-turbo and by all accounts can be troublesome.
As Leigh said the 1.9 is the venerable pump duse unit that powered everything VAG in the early 2000's and is generally very reliable. Of the facelift model the 140 came with a 6 speed box which is supposed to be stronger than the 5 speed in the lower powered variants. Still plugging away at the front suspension. Got lucky with the nearside drop link in that it wasn't seized enough to round off the spline drive recess needed to stop the ball joint turning while you undo it, not so lucky on the offside.
Two new Meyle HD drop links have been ordered but will delay refitting a couple of days. It's nice to be working on a vehicle I'm not relying on for work so when things like this happen it's not a disaster.
With both struts off the van I stripped them down. Top mounts seem ok and the bearings move freely so they'll be going back on. Took the opportunity to clean up the dampers and give them a lick of paint.
They're now ready to go back on when the drop links arrive.
The dog taking the opportunity to pinch is bed/my seat back.
Started tidying up a couple of engine bay trim panels and the brake backing plates. Unfortunately it was starting to get dark and the moisture in the air was playing havoc with the paint, most of it won't be seen so not a major problem.
Two new Meyle HD drop links have been ordered but will delay refitting a couple of days. It's nice to be working on a vehicle I'm not relying on for work so when things like this happen it's not a disaster.
With both struts off the van I stripped them down. Top mounts seem ok and the bearings move freely so they'll be going back on. Took the opportunity to clean up the dampers and give them a lick of paint.
They're now ready to go back on when the drop links arrive.
The dog taking the opportunity to pinch is bed/my seat back.
Started tidying up a couple of engine bay trim panels and the brake backing plates. Unfortunately it was starting to get dark and the moisture in the air was playing havoc with the paint, most of it won't be seen so not a major problem.
anonymous said:
[redacted]
Agreed on the scene tax, but that scene tax is nice come resale time. I've had mine for threee years, and I could easily sell it for what it cost me to buy and convert.Sorry to wander off topic OP, you're doing a great job. I quite fancy some H&R springs on mine, when can you come and fit them? I'll make you a cuppa.
LeighW said:
anonymous said:
[redacted]
Agreed on the scene tax, but that scene tax is nice come resale time. I've had mine for threee years, and I could easily sell it for what it cost me to buy and convert.Sorry to wander off topic OP, you're doing a great job. I quite fancy some H&R springs on mine, when can you come and fit them? I'll make you a cuppa.
Another point is when you do come to sell it it won't have turned quite as orange as the ford.
Trabi601 said:
LeighW said:
Trabi601 said:
Oh, VW vans can rust as well as the best of them.
T5s are galvanised. 
Was going to give working on the van a miss today after checking the weather forecast but as it turned out it was quite a nice day.
First up was an easy job. Higher spec models come with a supplimentary door seal which isolates the cabin a bit more and according to the blurb "makes it sound like a Golf door" its item 11 on the diagram below.
I was sceptical but it does improve the sound of the door closing, much less of a van rattle, whether it's any better on the road will have to wait.
These arrived yesterday
Which meant I could crack on with refitting the struts. Before they went back on I gave the arches a good clean. The amount of impacted crud in the turrets was impressive.
Continued with my fetish for painting everything I've removed from the van. The caliper carriers came up nicely
At the expense of my wire brush, ended up picking a few of the bristles out of my skin.
Got a picture looking up into the arch after I'd undersealed it, don't think it came out very well.
Everything went back together on both sides nicely. Ended up working in the dark again and my light also packed up so fitted the second side by feel. Will have to wait until tomorrow for pictures.
Will hopefully get the bumpers on tomorrow too.
First up was an easy job. Higher spec models come with a supplimentary door seal which isolates the cabin a bit more and according to the blurb "makes it sound like a Golf door" its item 11 on the diagram below.
I was sceptical but it does improve the sound of the door closing, much less of a van rattle, whether it's any better on the road will have to wait.
These arrived yesterday
Which meant I could crack on with refitting the struts. Before they went back on I gave the arches a good clean. The amount of impacted crud in the turrets was impressive.
Continued with my fetish for painting everything I've removed from the van. The caliper carriers came up nicely
At the expense of my wire brush, ended up picking a few of the bristles out of my skin.
Got a picture looking up into the arch after I'd undersealed it, don't think it came out very well.
Everything went back together on both sides nicely. Ended up working in the dark again and my light also packed up so fitted the second side by feel. Will have to wait until tomorrow for pictures.
Will hopefully get the bumpers on tomorrow too.
Started on the 240v hook up today. Live feed to the split charge system routed down the passenger side. Handily there's a couple of spare grommets that are perfect for the job.
Mounted the fuse next to the battery, looks reasonably tidy.
Next ran the cable for the incoming 240v. Decided to mount it on the drivers side as the max cable run to the consumer unit is 2m and I want everything under the drivers seat.
Decided to mount the plug to the airbox as access is easy and there's enough room.
And in situ.
Next up was to put the front back together, hoping I remember where this lot goes.
Offered up the painted bumper.
Bit fiddly as it was only me but it went on and all the fasteners found a home.
Then was able to get both front wheels on, the scuttle panel and wipers as well as various trim pieces to complete the front end. Only the one picture as it was getting dark, again.
Very happy with the way the front has turned out, the bumper looks factory fresh.
Mounted the fuse next to the battery, looks reasonably tidy.
Next ran the cable for the incoming 240v. Decided to mount it on the drivers side as the max cable run to the consumer unit is 2m and I want everything under the drivers seat.
Decided to mount the plug to the airbox as access is easy and there's enough room.
And in situ.
Next up was to put the front back together, hoping I remember where this lot goes.
Offered up the painted bumper.
Bit fiddly as it was only me but it went on and all the fasteners found a home.
Then was able to get both front wheels on, the scuttle panel and wipers as well as various trim pieces to complete the front end. Only the one picture as it was getting dark, again.
Very happy with the way the front has turned out, the bumper looks factory fresh.
Mark Benson said:
It's looking great.
Thought about solar for the leisure battery? I did it with ours and completely removed the need for a split charger, panel on roof has the battery fully charged every morning (running a fridge 24x7, lighting and charging tablet, phones etc.).
To be honest I haven't looked into it enough to go solar, one for the future. My wallet has been feeling the pain recently. Thought about solar for the leisure battery? I did it with ours and completely removed the need for a split charger, panel on roof has the battery fully charged every morning (running a fridge 24x7, lighting and charging tablet, phones etc.).
I've got all the big ticket items I want at the moment less an Eberspacher D2 which will probably be the next big purchase.
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