VW T25 restoration
Discussion
After many years of wanting a VW camper van (since I was 10!) i’ve finally taken the plunge and bought one! - Well, when I say bought one, I mean a rolling shell with stacks of boxes overflowing with nuts, bolts and parts that can only be described as ‘knackered’! What have I done??!
I’ve trawled the internet for the last couple of years trying to find the right one, thinking I could get a solid one that I can just get in and drive with very little work needed and then I buy this...
It’s probably quicker if I tell you what it does have fitted... Steel wheels, steering wheel and an engine but don’t stand behind when I start her up, you may never be seen again! Ok, so slight exaggeration but if you like fresh air and working lungs, take heed :-P
A luxury drivers seat (cushion optional and easy to valet) You’d be wrong if you thought it had a gear stick. That’s snapped at the base and has a metal tube slotted over the nub – I consider it an excellent security feature. Beat that Thatcham!
Looking very sorry for itself. Being optimistic though, the lights are on and work! That should satisfy My MOT guy... possibly.
Ok, so I set out around 2 years ago to find my perfect camper and i’ve bought this. I’d made offers for campers that were immaculate and fully kitted out but got rejected. Then I see this and within an hour, ive arranged a viewing, knowing full well that I was going to buy it. Insanity perhaps? I guess that’s part of it as i’ve tinkered with all of my other cars but nowhere near on the scale of this mammoth task
20 years ago, my father had a 7 seater VW Caravelle and we travelled everywhere in it. We had many trips to France and around the UK over the time that he owned it and although my mum was not a big fan of it, I thought it was fantastic!
Well, when I saw the front of this ... errm shell... on fleabay, I instantly emailed the seller, giving him the registration number of my dad’s Caravelle and asked if it was the same. When he came back to me and said it was, I felt like a kid in a candy store! The adrenaline kicked in and I knew I had to have it. We agreed in principal, an amount for it to be removed from Ebay and then I went to view it, dad in tow. When we started her up, despite the smoke bellowing out, the sound of the engine brought back so many memories and it would have taken a crowbar to remove the smile from our faces!
Here’s how she looked 20 years ago (taken in the Loire Valley, France) with me at the door!
So now it’s a waiting game for her to come home, albeit on the back of a recovery truck! I’ll post more when I start doing the work!
Excited is an understatement!
If anyone knows where I can find a gear stick (or full assembly), it would be much appreciated! Ive scoured the net and drawn a blank so far!
I’ve trawled the internet for the last couple of years trying to find the right one, thinking I could get a solid one that I can just get in and drive with very little work needed and then I buy this...
It’s probably quicker if I tell you what it does have fitted... Steel wheels, steering wheel and an engine but don’t stand behind when I start her up, you may never be seen again! Ok, so slight exaggeration but if you like fresh air and working lungs, take heed :-P
A luxury drivers seat (cushion optional and easy to valet) You’d be wrong if you thought it had a gear stick. That’s snapped at the base and has a metal tube slotted over the nub – I consider it an excellent security feature. Beat that Thatcham!
Looking very sorry for itself. Being optimistic though, the lights are on and work! That should satisfy My MOT guy... possibly.
Ok, so I set out around 2 years ago to find my perfect camper and i’ve bought this. I’d made offers for campers that were immaculate and fully kitted out but got rejected. Then I see this and within an hour, ive arranged a viewing, knowing full well that I was going to buy it. Insanity perhaps? I guess that’s part of it as i’ve tinkered with all of my other cars but nowhere near on the scale of this mammoth task
20 years ago, my father had a 7 seater VW Caravelle and we travelled everywhere in it. We had many trips to France and around the UK over the time that he owned it and although my mum was not a big fan of it, I thought it was fantastic!
Well, when I saw the front of this ... errm shell... on fleabay, I instantly emailed the seller, giving him the registration number of my dad’s Caravelle and asked if it was the same. When he came back to me and said it was, I felt like a kid in a candy store! The adrenaline kicked in and I knew I had to have it. We agreed in principal, an amount for it to be removed from Ebay and then I went to view it, dad in tow. When we started her up, despite the smoke bellowing out, the sound of the engine brought back so many memories and it would have taken a crowbar to remove the smile from our faces!
Here’s how she looked 20 years ago (taken in the Loire Valley, France) with me at the door!
So now it’s a waiting game for her to come home, albeit on the back of a recovery truck! I’ll post more when I start doing the work!
Excited is an understatement!
If anyone knows where I can find a gear stick (or full assembly), it would be much appreciated! Ive scoured the net and drawn a blank so far!
cat220 said:
Fantastic! What a great story, has to be something in that, meant to be!
I had a t25 Devon conversion for a few years. Loved it but sold it due to lack of use. Great vans.
Have a look on here: http://www.club80-90.co.uk/
Thanks for this cat220, ill get registered on there! it seems to be that people wait until someone is breaking theirs and then get the gear mechanicals off that! I had a t25 Devon conversion for a few years. Loved it but sold it due to lack of use. Great vans.
Have a look on here: http://www.club80-90.co.uk/
I bet you were gutted when you sold it
i'll be selling my car to fund this project and then using the camper daily! 
PeanutHead said:
Bookmarked.
My dad had an old rover back in the early eighties, probably making the rounds as a couple of tins of chopped tomatoes sitting on the shelf at morrisons now.
Glad you got round to starting the thread.
Haha!! love it Peanut! i've probably saved this van from the same fate!My dad had an old rover back in the early eighties, probably making the rounds as a couple of tins of chopped tomatoes sitting on the shelf at morrisons now.
Glad you got round to starting the thread.
Paddy_N_Murphy said:
Epic project - with bonus nostalgia.
When you think you have bitten off more than you can chew - http://www.ppcmag.co.uk/forum/viewtopic.php?f=7&t=9639
It sure is! hopefully I can pull it off! I can't get onto that link for some reason...When you think you have bitten off more than you can chew - http://www.ppcmag.co.uk/forum/viewtopic.php?f=7&t=9639
davepoth said:
Lovely story. OP, how solid is the shell? Looks pretty sturdy from the picture, had the previous owner got bored with a restoration or something?
shell is in pretty good shape. Underside is sold. It just needs slight attention to the bottom of the windscreen frame (rust about 4 inches where the seal sits) needs a new driver side step and rear wheel arches. Although they could be repaired with a bit of filler, i'd rather replace them and at £34 a panel, its probably just as cheap! Plus, I dont want to scrimp on it. I'd rather it be done to perfection.The previous owner had only had it a year and had stripped it down to respray and convert to a camper but something happened (not with the van) and he just wanted rid. Prior that, it had been stored for 8 years.
marky911 said:
Brilliant!
What are the chances of finding that eh? I'm sure there'll be headaches and swearing along the way but it will be mega rewarding too bring it back up to scratch. Good luck, I'll be watching with interest.
I never liked the T25s much either (well compared to the older ones) but, after realizing how slow the bays and splits are it was my only option really.
Just picked this up 3 weeks ago. Converted panel van. Really well thought out and has a 2.5 Subaru Legacy engine in the back.
Off to France and Switzerland in 4 weeks (hopefully). Can't wait.
I'd practically given up searching for it. Ive always wanted a splitty but they're all way more than I can afford. I'd never really thought about getting a bay, its always been a split or a T25 and its fantastic that I can bring this one back to life! Hopefully getting it delivered at the weekend. What are the chances of finding that eh? I'm sure there'll be headaches and swearing along the way but it will be mega rewarding too bring it back up to scratch. Good luck, I'll be watching with interest.
I never liked the T25s much either (well compared to the older ones) but, after realizing how slow the bays and splits are it was my only option really.
Just picked this up 3 weeks ago. Converted panel van. Really well thought out and has a 2.5 Subaru Legacy engine in the back.
Off to France and Switzerland in 4 weeks (hopefully). Can't wait.
Your van looks in top condition and with a 2.5 legacy in i bet its not lacking power! what does it churn out? 150BHP? I hope you have a great time touring round. Thats something I hope to do in the not too distant future!
Paddy_N_Murphy said:
if yours needs the work the link shows, I would slowly turnaround and run. Run like the wind !!!!
haha! I surely would have done! they're brave for taking that on. im a man with moderate knowledge when it comes to cars so it will be a steep learning curve. im also going to take some welding lessons from a mate who has restored a bay window from pretty much the same condition so hopefully I can do a lot of it myself and feel the pride!marky911 said:
Late reply, bloomin' nightshifts! 
Yes my van had a full body refurb about 4 years ago, including all new panels etc and a respray in Audi Polar white. Unfortunately it already has very minor beginnings of seam rash in 1 or 2 places, but at least I know the whole shell is metal, no filler at all. I think these vans are a constant project, especially body wise.
The camper conversion and engine conversion were done 5000 miles ago, so barely run in. It's a 165bhp n/a Legacy engine but still on the vw 4 speed box. It uses a proper bellhousing conversion not just an adaptor plate and the box and diff are strengthened but since the box was designed for 70bhp I don't do any racing starts. 
Great power though.
Vanagon, are you restoring the van to standard original condition or are you doing a camper conversion? To be honest what we are learning is all you really need in the van is a bed. We have a drive-away awning for seating, eating and cooking, as we have a plug in electric stove and there is also an external gas outlet for a gas stove. The fridge and sink in the van are handy but you can buy a plug in fridge anyway, 12v or mains.
I take it you're leaving the original colour scheme since that's how you remember the van? I would and it's a cool retro colour anyway. Looks great.
Do you have a timescale in mind or are you just taking it as it comes? Big project!
Work always gets in the way! Yes my van had a full body refurb about 4 years ago, including all new panels etc and a respray in Audi Polar white. Unfortunately it already has very minor beginnings of seam rash in 1 or 2 places, but at least I know the whole shell is metal, no filler at all. I think these vans are a constant project, especially body wise.
The camper conversion and engine conversion were done 5000 miles ago, so barely run in. It's a 165bhp n/a Legacy engine but still on the vw 4 speed box.
It uses a proper bellhousing conversion not just an adaptor plate and the box and diff are strengthened but since the box was designed for 70bhp I don't do any racing starts. Great power though.Vanagon, are you restoring the van to standard original condition or are you doing a camper conversion? To be honest what we are learning is all you really need in the van is a bed. We have a drive-away awning for seating, eating and cooking, as we have a plug in electric stove and there is also an external gas outlet for a gas stove. The fridge and sink in the van are handy but you can buy a plug in fridge anyway, 12v or mains.
I take it you're leaving the original colour scheme since that's how you remember the van? I would and it's a cool retro colour anyway. Looks great.
Do you have a timescale in mind or are you just taking it as it comes? Big project!
Sounds like you got yourself a good one and it really is a head turner. I've never been a fan of white on cars/campers but have to say, yours looks brilliant! I looked at one with the 2.2 legacy engine in but wasn't entirely convinced by it - especially seen as the owner was clearly tax dodging as it was still registered as a 1.9! Would be nice to have the power for hills but im not looking for speed.
Im going to do it as a camper conversion but im shying away from adding the external power supplies. Just a few cupboards with integrated stove, pull out table of some sort and a 3/4 rock 'n' roll bed.
Im really undecided about the colour scheme. Part of me wants to keep it the same colour but then the other side wants to go bold and have it orange and white - I think from what i've seen, they did the devon campers in that scheme and I want it to stand out so I was thinking Ford Focus ST orange.
I've given myself an initial timescale of 3-4 months to get the welding, respray, engine and gear lever sorted so that I can get it up and running, at which point I then have to sell my car to get more funds to complete the inside and although i've not really thought about timescale for that, i'd like to complete it all within a year. When I picture it now, it doesn't seem that daunting though i'm sure when it arrives, i'll go back to thingking 'what the hell have I done?!' haha!
egor110 said:
What a brilliant story, please keep it the original colour.
This van's part of your family history, hopefully your children will have there holidays in it and eventually it will be handed down to them.
Thanks egor110. I think i'm opting for the colour change instead of the original colour. Its a shame to change it because of the history but I will be happier with colour. The history will still be there everytime I look at the registration. I would love my children to inherit this one day. (I dont have children yet lol!) This van's part of your family history, hopefully your children will have there holidays in it and eventually it will be handed down to them.
marky911 said:
Vanagon said:
Work always gets in the way!
Sounds like you got yourself a good one and it really is a head turner. I've never been a fan of white on cars/campers but have to say, yours looks brilliant! I looked at one with the 2.2 legacy engine in but wasn't entirely convinced by it - especially seen as the owner was clearly tax dodging as it was still registered as a 1.9! Would be nice to have the power for hills but im not looking for speed.
Sounds like you got yourself a good one and it really is a head turner. I've never been a fan of white on cars/campers but have to say, yours looks brilliant! I looked at one with the 2.2 legacy engine in but wasn't entirely convinced by it - especially seen as the owner was clearly tax dodging as it was still registered as a 1.9! Would be nice to have the power for hills but im not looking for speed.
marky911 said:
Erm, interesting point that. Mine is still a 1.9 petrol on the V5. I asked my insurance about that and they said they don't care what it says on there as long as I declare all the mods inc. engine upgrade. I've sent them a detailed info pack on the conversion. I can have any engine in there upto 2.5L and it doesn't affect anything.
I'd never thought about the tax side of it though. I'll look into it.
haha, I hope I didn't offend with that comment. It wasn't my intention. I was just very reluctant to buy it knowing that the wrong tax was being paid. I work for one of the leading insurance companies and I know we wouldn't do anything about the tax side as long as we knew what the correct engine size was.I'd never thought about the tax side of it though. I'll look into it.
Vanagon said:
Im really undecided about the colour scheme. Part of me wants to keep it the same colour but then the other side wants to go bold and have it orange and white - I think from what i've seen, they did the devon campers in that scheme and I want it to stand out so I was thinking Ford Focus ST orange.
marky911 said:
Sounds cool! You could go wild on the interior with that colour scheme. White vinyl or leather with orange centre sections and orange piping.
That's the only thing I would have done differently with mine if I'd done it. It's just grey, where as if you're going to all that bother it's a shame not to do something jazzy.
I think i've pretty much decided to go for the orange and white so I am looking to do something funky with the interior as the gold/brown seats and door cards wont really go. I'll be trying to do it all myself so I better get learning on the sewing machine! hahaThat's the only thing I would have done differently with mine if I'd done it. It's just grey, where as if you're going to all that bother it's a shame not to do something jazzy.
Vanagon said:
I've given myself an initial timescale of 3-4 months to get the welding, respray, engine and gear lever sorted so that I can get it up and running, at which point I then have to sell my car to get more funds to complete the inside and although i've not really thought about timescale for that, i'd like to complete it all within a year. When I picture it now, it doesn't seem that daunting though i'm sure when it arrives, i'll go back to thingking 'what the hell have I done?!' haha!
marky911 said:
Wow! 3-4 months sounds tight. You must be handier than me. I've had mine a month I think and am still working through my list of minor upgrades/niggles.
Good luck. It will be one cool van once it's done.
Im hoping it's going to be 3-4 months for the basics to be done. I've picked up the van now and inspected every panel and it doesnt need as much welding as I first thought, which is a bonus! With these vans, im sure there will be little bits and pieces that i'll always want to add! I've had mine a month I think and am still working through my list of minor upgrades/niggles.Good luck. It will be one cool van once it's done.
Well, she's finally home! And typically, it didn't rain until it was on the recovery truck and the heavens opened!
Unfortunately, I didnt manage to take a picture sat on the driveway as I was too busy letting the tyres down to get it in the garage. - it fits with literally millimeters to spare! We managed to smoke out the entire street getting it in there as the choke on the carb is shot. I literally couldnt see my hands! Despite this, I still couldn't stop smiling!
After a thorough check of the bodywork, its actually not as bad as I originally thought. Only the drivers step and the front panel needs to be welded. The wheel arches, which I thought needed replacing have only rusted slightly and not all the way through so I may get away with a thin coat of filler. (not ideal as I wanted it to be filler free but i'll see how it turns out!)
Here's a few more close ups to show the condition. I'll add some more when I get her out of the garage again - which will be when i've bought a fire extinguisher and attempted to repair the choke!
Nice tidy floor. Only very minor bubbling in the paint and no rust at all on the underside.
I think this is the only picture that scares me! You can actually see on the accelerator, where chemical metal was used when my father owned it, to re-attach it as it fell off!
Rusted driver step - better picture to follow
I'm pretty certain that the garden hosepipe fitted (middle left, between the HT leads) shouldnt be there!
All the panel seams have been coated with rust proofing when the previous owner was sanding the bodywork down. Although I like the fact that you can see the joins in these vans, I've seen a couple of other vans where they have been filled flat so they're not visible. Im after suggestions on this as to what you think about doing this and also, what I would use if I decide to do it...
Unfortunately, I didnt manage to take a picture sat on the driveway as I was too busy letting the tyres down to get it in the garage. - it fits with literally millimeters to spare! We managed to smoke out the entire street getting it in there as the choke on the carb is shot. I literally couldnt see my hands! Despite this, I still couldn't stop smiling!
After a thorough check of the bodywork, its actually not as bad as I originally thought. Only the drivers step and the front panel needs to be welded. The wheel arches, which I thought needed replacing have only rusted slightly and not all the way through so I may get away with a thin coat of filler. (not ideal as I wanted it to be filler free but i'll see how it turns out!)
Here's a few more close ups to show the condition. I'll add some more when I get her out of the garage again - which will be when i've bought a fire extinguisher and attempted to repair the choke!
Nice tidy floor. Only very minor bubbling in the paint and no rust at all on the underside.
I think this is the only picture that scares me! You can actually see on the accelerator, where chemical metal was used when my father owned it, to re-attach it as it fell off!
Rusted driver step - better picture to follow
I'm pretty certain that the garden hosepipe fitted (middle left, between the HT leads) shouldnt be there!
All the panel seams have been coated with rust proofing when the previous owner was sanding the bodywork down. Although I like the fact that you can see the joins in these vans, I've seen a couple of other vans where they have been filled flat so they're not visible. Im after suggestions on this as to what you think about doing this and also, what I would use if I decide to do it...
Well, after about an hour trying to remove the spare wheel from under the front (bolt was rusted solid) ive managed to get it off with WD40 and brut force and get the gear stick mechanicals out. Taken some advice from 'Just T25's' in Birmingham and they're going to weld the gearstick by inserting a solid metal rod inside. They seemed pretty confident that it wouldn't snap so i'll give it a go. At least it will do until I source a new one.
Image of the gear link housing. 4 tiny bolts and off it comes! Though it would have been useful to have a ratchet with an extender bar as the water pipes were a bit tricky to get around. - next thing on my shopping list!
After removing the box. Only a slip pin holding it in place.
Linkage completely removed
The offending parts!
Im really amazed at how easy that was to take out and should be just as easy to put back - a roadside repair would be a breeze... if you carry a spare! Might be worth considering seen as they're prone to snapping!
So, thats being sent off for repair and as the standard pierburg 2e3 carb is shot, the same company recommended a weber carb in replacement as they're better (apparently!) Not exactly cheap but as I would have spent £200 getting the old one fixed, the new one isn't that much more.
Whilst im waiting for these to be sent to me, i've already made a start on the bodywork. All of the panel seams are to be flush with the body. I've chosen to do this as I think it will look better and also, the seams are the places that get hit hardest with rust so hopefully it will offer a bit more protection.
I'll get some pictures of the bodywork up soon!
Image of the gear link housing. 4 tiny bolts and off it comes! Though it would have been useful to have a ratchet with an extender bar as the water pipes were a bit tricky to get around. - next thing on my shopping list!
After removing the box. Only a slip pin holding it in place.
Linkage completely removed
The offending parts!
Im really amazed at how easy that was to take out and should be just as easy to put back - a roadside repair would be a breeze... if you carry a spare! Might be worth considering seen as they're prone to snapping!
So, thats being sent off for repair and as the standard pierburg 2e3 carb is shot, the same company recommended a weber carb in replacement as they're better (apparently!) Not exactly cheap but as I would have spent £200 getting the old one fixed, the new one isn't that much more.
Whilst im waiting for these to be sent to me, i've already made a start on the bodywork. All of the panel seams are to be flush with the body. I've chosen to do this as I think it will look better and also, the seams are the places that get hit hardest with rust so hopefully it will offer a bit more protection.
I'll get some pictures of the bodywork up soon!
mike9009 said:
Personally i wouldnt de-seam your van. It would always raise suspicions for me as to whether it was rusting badly underneath or not, although you are saying this van is a keeper?
Also i prefer the seams on older vehicles, gives them more character and orinal feel. I always hated original minis that had been deseamed.
Glad your van looks better than you thought and much better than the restoration project posted earlier!
Keep us updated....
Mike
Hi Mike! Also i prefer the seams on older vehicles, gives them more character and orinal feel. I always hated original minis that had been deseamed.
Glad your van looks better than you thought and much better than the restoration project posted earlier!
Keep us updated....
Mike
I was really undecided about doing it but one of the rear panels does have some rust spots near the seams. Ill put a pic up so you can see. I dont think it justifies a panel replacement but it looks really tatty. Im taking pictures galore of the work im carrying out to it so if I did ever decide to sell (which I doubt) there will be plenty of pictures to see as to the condition. I think without these, i'd be dubious about the state of it behind the paint!
Overall, im making good progress but thats largley down to it being such a solid shell and chassis.
Is there another restoration project on here at the moment?
Driver side rear
Its been a while since I put anything up on here so I thought i'd just add a couple!
This is how the driver side lower rear wing looked when I bought the van...
And after about 6 hours of filling and sanding, heres what it looks like now.
There's hardly any filler on there to be fair. Its mainly in the seams and then feathered off to provide a smooth finish. Its still not quite perfect but the primer has been put on to show the imperfections so I can finish it off.
Im really happy at how this has turned out! but its taking a lot longer than I thought it would!
and for those eagle eyed viewers, yes, I even managed to cut the bushes back outside the garage! lol
This is how the driver side lower rear wing looked when I bought the van...
And after about 6 hours of filling and sanding, heres what it looks like now.
There's hardly any filler on there to be fair. Its mainly in the seams and then feathered off to provide a smooth finish. Its still not quite perfect but the primer has been put on to show the imperfections so I can finish it off.
Im really happy at how this has turned out! but its taking a lot longer than I thought it would!
and for those eagle eyed viewers, yes, I even managed to cut the bushes back outside the garage! lol
Gassing Station | Tents, Caravans & Motorhomes | Top of Page | What's New | My Stuff