VW Transporter Day Van Conversion
Discussion
Have you done the front springs yet, it's apparently a PITA to do them?
Bungleaio said:
jamiebae said:
Looks good, you're certainly doing the job properly. I've got my eye on a new California but as a one car family it's a bit on the big side sadly.
I rented one for the weekend, it's a viable alternative to actually owning one. I would love one though so I'm keenly watching these conversion threads.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.
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.
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.
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.
Got a couple of jobs ticked off today.
First was an annoying bit of rust running along the bottom of the sliding door. There's a tube that runs from the extrenal handle down to the drain hole in the bottom of the door, I'd assumed that it had got blocked up but all looked clear so no obvious reason that I could find.
To gain access the door had to come off, not difficult just a bit twitchy that close to the bodywork.
And a close up of the worst part.
Used a flap disc to remove all the paint and rust. Was contemplating giving it a skim of filler but due to its location it will barely be seen and most of it will be covered by ply so didn't bother.
A couple of coats of primer, 3 coats of VW Reflex silver and 4 coats of laquer later it was looking much better.
Needed 3 hands to reattach it but just to prove I managed it.
In between waiting for the paint to dry I made a start on the cab. First job was sound deadening the floor.
I couldn't justify the cost of Dynamat or Silent Coat so I used Flashbond, the lead replacement flashing. The cab took 1 roll which was £10, even if it's 50% as good as dynamat I'll be happy.
With that job done I could refit the flooring and side steps.
Amazing what a difference that made.
I've bought a tracker which I'll fit tomorrow along with reassembling the dash and progressing a bit more with the electrics.
First was an annoying bit of rust running along the bottom of the sliding door. There's a tube that runs from the extrenal handle down to the drain hole in the bottom of the door, I'd assumed that it had got blocked up but all looked clear so no obvious reason that I could find.
To gain access the door had to come off, not difficult just a bit twitchy that close to the bodywork.
And a close up of the worst part.
Used a flap disc to remove all the paint and rust. Was contemplating giving it a skim of filler but due to its location it will barely be seen and most of it will be covered by ply so didn't bother.
A couple of coats of primer, 3 coats of VW Reflex silver and 4 coats of laquer later it was looking much better.
Needed 3 hands to reattach it but just to prove I managed it.
In between waiting for the paint to dry I made a start on the cab. First job was sound deadening the floor.
I couldn't justify the cost of Dynamat or Silent Coat so I used Flashbond, the lead replacement flashing. The cab took 1 roll which was £10, even if it's 50% as good as dynamat I'll be happy.
With that job done I could refit the flooring and side steps.
Amazing what a difference that made.
I've bought a tracker which I'll fit tomorrow along with reassembling the dash and progressing a bit more with the electrics.
Barchettaman said:
You're flying through it - fantastic work.
Another RC thread where, although I have no need of a similar vehicle, I bet if I had one suddenly I'd find a gazillion fun things to do with it!
In the same way a dog gets you out the house I'm hoping this is the excuse I need to explore a bit more. Another RC thread where, although I have no need of a similar vehicle, I bet if I had one suddenly I'd find a gazillion fun things to do with it!
Another couple of quick jobs ticked off.
With added scene tax!
Also changed the bonnet stay for a gas strut, 5 minutes work but so much better.
And last night I sound deadened the ceiling.
I've also filled the ceiling ribs with expanding acoustic foam. May even add a few Nm to the torsional rigidity who knows.
With added scene tax!
Also changed the bonnet stay for a gas strut, 5 minutes work but so much better.
And last night I sound deadened the ceiling.
I've also filled the ceiling ribs with expanding acoustic foam. May even add a few Nm to the torsional rigidity who knows.
LeighW said:
Have you bought the windows yet? I fitted a slider on the driver's side and a fixed on the passenger side, and tbh I wish I'd put a slider on both sides - it can get quite warm in the back.
Yes but I've gone for fixed all round, possibly a mistake although my van doesn't have AC which I'm now thinking is probably a mistake so I've been looking at Truma Saphir AC and heating units in one, would probably fit under the floor. Heard there are problems with the sliding windows leaking although this might just be genuine ones. My intention would be to open the side door if it got too hot.
gpb1 said:
ChocolateFrog - could you do me a real favour. I want to fit a fabric pull strap in the back for my rear passenger to hold on to when cornering (my rock-n-roller seat is vinyl and quite slippy). I need to find one of the larger holes under the rear window behind the pillar for the sliding door to attach the strap via (using a threaded rivnut hopefully). As you've got your van stripped out, could you take a picture with a ruler/tape measure below it to give me a fighting chance of drilling through the board and carpeting that's glued in place in my van. Ta
You might be a day too late. I think I covered it up with insulation today! I'll check tomorrow but pretty sure they've been covered over.Gassing Station | Readers' Cars | Top of Page | What's New | My Stuff