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Thread: Itís only supposed to be a parts van for the project van

  1. #41
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    Dec 2009
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    Ive got 3.5 vans here as well.

  2. #42
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    If Robs Back doors are Minging after 13 miles ... I suspect Green doors might be the same at 1.3 miles

  3. #43
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    Feb 2011
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    Quote Originally Posted by snuffegull View Post
    Not bad for a parts car!
    Thanks mate

  4. #44
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    Quote Originally Posted by ScotClayShooter View Post
    If Robs Back doors are Minging after 13 miles ... I suspect Green doors might be the same at 1.3 miles
    At least robs is only the back doors. Green doors will be the whole passenger side of the van.

  5. #45
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    Feb 2011
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    Notched the O/S chassis leg today. I’ve still got to lift the rear engine mount.
    I’ve been in talks with a parts company about rear arch repair panels, I’ve managed to get them to give me a decent discount so I’ll be ordering 2 sets, one for me and one for Rob’s van. I’ve also just been talking to a guy about helping me with the body prep for this one. It’s going to end up getting a full blow over later in the year. This does mean I’ll end up loosing the sign writing on the doors which I’m a little sad about but I might redo them with a different logo.

    For the notch I used a 68mm hole cutter and a bit of 4mm wall tubing. I epoxy primed it then stone chipped.







  6. #46
    Join Date
    Feb 2011
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    Rob stopped by last night and I made a start on raising the rear engine mount. We got it all done but I didn’t have a bolt long enough. Now the bolt that is used has a thread on the head of it for a bracket to bolt to. The bracket looks to hold a breather hose of some sort.

    You can kind of make out the bracket in this photo.



    Rob said he just removed his bracket but I didn’t want to do that so tonight after work I bored and threaded (m6) a hole in the head of a new longer m10 bolt. I locktited a m6 thread in it so once I had the bolt back in the engine mount I could re fit the bracket with a new m6 mudguard washer and locknut.





    I refitted all the pipework I’d removed to get access to the mount then sat it on the floor to see the ground clearance. The sump is now sitting just above the subframe. It’s got roughly 57mm of clearance.
    Next is to get a new oil filter and swap the sump for the shallow one.

    I’ve also removed the front wheels and adapters. I’m taking the adapters to work to get them milled down. I’m going to go from 18-15mm on the front.

  7. #47
    Join Date
    Feb 2011
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    I did a bit more to the paint work this morning, I’ve only got the passenger door and wing left. I was going to finish them but the da fell over and the pad spun into the grass/dirt.
    It’s made the paint shine a bit but it’s still a mess really. It’s full of scratches still from the previous owner washing it with a scouring pad.



    I’ve got some spigot rings on the way and some rear camber shims. Hopefully I can get them all fitted and the adapters milled down ready for skegvegas next Friday.

  8. #48
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    So it’s skegvegas tomorrow and I’ve still not got the van ready. I got my dad to mill the front adapters down from 18mm to 15mm yesterday. Unfortunately it took most of the head off the 4 Allen bolts that hold the slug in so tonight after work I had to weld some m8 nuts to them to get them out. I ordered some new shallow head bolts this morning from BAPP and the rep dropped them off on his way home tonight. I still had to put each one in the lathe and skim a bit off each one.
    I’ve also had to skim a bit off the head of the 3 big Allen bolts so that they sit flush in the adapter.







    My spigot rings came at some point I don’t know when but they have been on the kitchen side all week and the Mrs didn’t tell me.

    So tomorrow morning I need to try and roll the arches, fit the front adapters and the wheels back on. Remove the rear wheels and fit the camber shims that I picked up today. I might as well replace the rear wheel cylinders whilst I do the shims. I’ve still got the passenger door and wing to mop and polish. I tried a paint sealer on some parts that I’d done at the weekend and it’s worked pretty well. It’s some stuff ford use to protect new vehicles.




  9. #49
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    Feb 2011
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    Just got back from Viva Skegvegas, great weekend.
    Friday morning I was busy fitting the front adapters and the Pontiac wheels back on. I’d wanted to fit the rear camber shims but I didn’t have a socket big enough for the rear hub nut so I’ll have to do them in the week.
    I also mopped and polished the passenger door and wing and gave it a wash and paint sealant in the areas I’d not done in the week.
    The drive to Robs was alright but I’ve got some rubbing issues. The front tyres are rubbing the arch liners and the rear arches are touching the tyres on bumps. The rear should be ok once the shims are fitted and I’m going to try my adjustable top mounts on the front.

    This thing decks out on the road quite a bit, loads more than my other van used to and the other van was much lower.



    Scraped quite a lot getting on the drive.


  10. #50
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    Feb 2011
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    I took the van to edition 38 last weekend. Rob took my mk3 as his vans gone pop. Had a great time and met a few caddy owners. I did want to fit my adjustable top mounts and rear camber shims before we went but it didn’t happen. The top mounts didn’t fit properly so we abandoned the idea and just set off. The drive was fairly uneventful, I ripped a cats eye up overtaking someone. The front drivers side tyre rubbed the arch liner the whole way there. Rob said at junctions he could smell the rubber. We fixed it at the show with a ratchet and extension bar and by loosening the wing bolts and pulling it out a little.

    The van went on the show field Saturday, I was told it might win an award for worst abomination on the show field. Lolol






  11. #51
    Join Date
    Feb 2011
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    I finally got to see underneath the van this week. I took it to get the tracking done but the tie rods have corroded so much there’s no thread left to adjust it. So new rods are on the shopping list.
    It’s not pretty underneath. The rear subframe mount on the passenger side is rotten and the subframe is slightly bent now. The drivers side has been bodged in the past. I’m guessing because the fuel lines run in the chassis that side they decided the best thing to do was cut the end of the subframe off and fill the hole with silicone



    I’m going to have to plate the subframe as it’s taking a battering









    The shallow sump will soon have to go on as well. My old man covered the lane at work in road plainings and the odd bit sticking up is bouncing off the sump
    Engine




    Even the fuel tank is getting scuffed




  12. #52
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    Feb 2011
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    I’ve got a bit of a wiring issue at the minute. Last night I hit a really bad section of bumps on a back road and smashed the subframe and sump into the toad. I killed the engine straight away just in case the sump had gone. I jumped out and saw oil on the toad behind me, quick look under the van and the sump was fine just had some gravel rash.
    I got back in and went to start it up and nothing happened, all lights on the dash went off. I spent ages messing about with it before it started.
    This morning I got in to come to work and it started fine. I switched the lights on and the radio, heater fan and window wipers stopped working. I put the lights on side light and everything came back on. I’m guessing it possibly a loose fuse or something.

  13. #53
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    Feb 2011
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    Van seems to be running and working ok again. Not really sure what went on with it.
    Rob gave me a spare steering rack with tie rods so I nipped down my mates workshop today and removed the tie rods. I ran a tap down them to clean the threads and cut a bit extra. Hopefully I can get them fitted next week, don’t fancy doing them on the drive in the rain today.
    Unfortunately on the way home a lorry threw a stone up and it’s chipped the window screen




  14. #54
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    So Friday night I made a start on swapping the tie rods, I did the drivers side first. The old rod cane out easily, so easy in fact I thought the tool I had borrowed wasn’t working I literally unscrewed it by hand. I got the new one in, wound the ball joint right down on it, put the wheel back on and sat it on the ground and was met with this



    I tried to adjust it but the ball joint was bottomed out. I then realised the new rods were 20mm longer than the old ones

    Whilst I had it jacked up I made a start on plating the subframe









    That should last a few months.

    Saturday morning I borrowed a M14x1.5 tap from my mate, I cut just over 20mm from the end of each new rod and ran the tap down about 20mm. It’s seems to have done the job.
    I was planning on repairing the subframe and chassis where the subframe bolts on on the drivers side but I got side tracked scraping bubbling under seal off. This revealed the carpet under the drivers seat



    I ground it all back then made some plates out of 2mm sheet. It was a bit of a bitch to weld when the wax oil melted and started dripping out of the hole. Whilst underneath I had another look at the passenger side. It’s going to take some work, the jacking point is flat, the chassis rail is like Swiss cheese and where the body meets the cill it’s all bent. Just a bit of cutting and welding it will be fine. I’m going to treat it all with Bilt Hamber hydrate 80 rust killer then epoxy prime, seam seal, prime then stone chip it. Hopefully it will outlast my ownership.
    Whilst looking at this side I saw that I need a new tyre already



    They have only been on since July I think. I should have had the tracking done a long time ago.

    I’ve got an old repair on the drivers side to re do as it’s terrible. I pulled this lump of silicone out of a hole






    I’m getting grief from the Mrs, she wants to know why I’m repairing a van that I’m only supposed to be driving until the mot runs out in January. She also keeps saying I thought it was meant to be a parts van? She won’t be pleased when she realises I’m going to re paint it
    Last edited by mitty85; 14-10-2018 at 04:29 PM.

  15. #55
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    Feb 2011
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    I’ve not done much to the van the last few weeks as I’ve been busy or the workshop has been full. I’ve bought a new pair of tyres but I didn’t check the advert properly and they are ns20’s not ns2’s like what’s already fitted.
    I’ve also decided that the spares van should be quicker so I’ve gone and got a big turbo and I’ll fit the .240 injectors I already have.







    I think I’m going to weld it to a manifold to fit it. I’m also planning on building an inlet manifold like Rob is currently doing.

  16. #56
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    I met Tontoe recently and picked some parts up from him for my project van which means the .240 injectors from that will now be fitted to this (.280’s to go on the project van). I also got a rear headliner from him so I’ll fit it in this for now as I don’t really have space to store it.



    Progress has stopped on this at the minute as I’ve not been able to get it in the workshop to finish the welding work. Hopefully I can get it done by the new year as it needs an mot in January.

  17. #57
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    that silicone was from a tyre?!

  18. #58
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    Quote Originally Posted by 13 View Post
    that silicone was from a tyre?!
    no it was from a hole in the chassis

  19. #59
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    Jun 2009
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    surfing the forum when I should be writing reports..... (Aylesbury or Lincoln)
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    I've seen your van a number of times around and about. I live in Lincoln but I can't recall exactly where or when I've seen it. I used to own Swainys van.
    I officially owe Mk2 Pickup a pint!

    Check out my van tread: http://www.vwcaddy.com/showthread.php?t=54410

  20. #60
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    Feb 2011
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    Quote Originally Posted by Village View Post
    I've seen your van a number of times around and about. I live in Lincoln but I can't recall exactly where or when I've seen it. I used to own Swainys van.
    You probably saw it when Eliot the previous owner had it he lives in north greetwell. He had it a few years, I used to go to college in it on a Tuesday night in Lincoln back in September but the back roads from horncastle/Woodhall Spa we’re giving it a right battering.

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