Our camper build

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Our camper build

Postby phil miller » 03 Jun 2012, 21:59

Hi all had our 88 E plate camper for a few weeks now, i think it started as a petrol and at some point converted to Diesel, there is no glow light on the dash, fuel filter housing is wrong (its a mk3/mk4 golf style filter) and the wiring is a mess

Now it had no engine in it so the hunt was on for a new engine, after reading on here we decided to go for a 1Z/AHU we found a 95 plate mk3 golf TDI 1Z on ebay close ish and got it cheap, the plan is have the engine, loom, ecu and everything needed and scrape the rest, so it will be a cheapish engine

The last week has been a little epic, post man must think im taking the mick lol
here is some of the last weeks purchases

Image

ive got cam and crank oil seals, spigot ring, cool thermostat, block bung and flywheel bolts from Brickwerks
Clutch and Flywheel from mike on here :ok
Clutch Slave cylinder (our one is siezed solid)
Sump gasket
rear shoe spring kit
O/S engine mount
TD sump and oil pump from Kline on here (top bloke)
Mk3 golf TDI
and a set of Merc rims (bought while drunk last saturday)

so i dont start my new job till a week monday (VW indy :P ) so my plan is tomorrow to get the Engine out of the golf, all the not need golf parts removed and T25 parts fitted, then Tuesday i want to get the engine sat in the engine bay, coolant hosed up and the wiring sorted, wednesday will be to fab up the Exhaust system and N/S mount, have Thursday and Friday off, then saturday fit the new cambelt kit and collect the starter motor from kevtherev then start the bus up, thats the plan and aim, will keep this up to date with plenty of pics along the way, im sure there will be parts ive forgotten or break but time will tell, any help or info is most welcome
1988 Matt Black, T25 caravelle, Living the dream
Wanted diesel sump and oil pick up PM me if you can help
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Re: Our camper build

Postby 16vmini » 04 Jun 2012, 16:52

will keep checking , (would be nice in a build forum lol )

good luck..

you keep same gearbox for now then ?

Matt
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Re: Our camper build

Postby phil miller » 04 Jun 2012, 17:44

Hi Matt yeah keeping the same 4 sp gearbox, will see what its like once its all running, at Live it Dub it and member Graham on here told me about using a 6sp passat gearbox, im thinking that thro atm just incase the 4 sp is a mare

Today has seen a fair size step forward, and as normal a couple back, first here are some pics of my progress today
This is what i started with
Image

So after removing the front end and disconnecting the pipe work, 2 coffees, 3 fags, 95 skinned knuckles and one cross word with my old man later :rofl (only joking) we had this
Image

I then set about taking the box, clutch, flywheel, sump and oil pump off
Image
Then my first headache of the day came, i wanted to replace the rear main oil seal, id got one from Brickwerks and it was wrong DOH, also i didnt bother to wash my hands before opening it so its gonna go in my box of stuff lol
anyway sump, pump, spigot bearing, flywheel and clutch all went on well, progress at last,
Image
i then decided to fit the o/s engine mount, next headache arrives, my engine has the oil cooler and where the pipes go onto the block there isnt space to have them and the mount

Image
so if anyone has any ideas id love to hear them :ok , time was moving on and i had to be home for 4 as a friend was due over,so i started to get the loom out the golf and i sat the engine in the middle of the bus
Image
so tomorrow, the engine is gonna be lifted in and bolted up, i will start to fab up the n/s mount and fab the exhaust pipe ive got planned, will get the loom out of the golf and strip it down and hopefully start to connect the coolant hoses up to the engine, its going ok, just the little headache on the coolant hose lay out but i hope some one can help with advice on that
1988 Matt Black, T25 caravelle, Living the dream
Wanted diesel sump and oil pick up PM me if you can help
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Re: Our camper build

Postby 16vmini » 04 Jun 2012, 17:53

two quick options without know the complete story of these conversions :

1) make a new mount to miss pipes
2) remove oil cooler for now ?

Matt
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Re: Our camper build

Postby phil miller » 04 Jun 2012, 17:58

16vmini wrote:two quick options without know the complete story of these conversions :

1) make a new mount to miss pipes
2) remove oil cooler for now ?

Matt


Matt i like your thinking :ok , i wanna keep the cooler, but modding/ making a new o/s mount is a great idea, i hadnt thought about that (long day lol) will have a look first thing tomorrow well im fresh so to speak
1988 Matt Black, T25 caravelle, Living the dream
Wanted diesel sump and oil pick up PM me if you can help
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Re: Our camper build

Postby 16vmini » 04 Jun 2012, 20:46

assume you can weld , so making things aint a problem

keeping the Tdi as std as possible is always good... so modding mount would be better in my guess at moment :)

should be simple enough with a mig welder :)

Matt
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Re: Our camper build

Postby phil miller » 04 Jun 2012, 21:11

Yeah mate welding isnt a problem, ive got my own welder and i already have to do the n/s, will make a rep of the o/s but with less webbing so i will be able to connect the bottom hose and oil cooler pipe, tomorrow will be a fun day :ok
1988 Matt Black, T25 caravelle, Living the dream
Wanted diesel sump and oil pick up PM me if you can help
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Our camper build

Postby 16vmini » 05 Jun 2012, 10:43

So how is the day going ?
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Re: Our camper build

Postby phil miller » 05 Jun 2012, 17:02

16vmini wrote:So how is the day going ?


Just got home (vans at my mums, 20 miles away :cry:)

Right the engine is bolted to the box and sat in place, the weather was awful and being outside made life harder, also i dont have the T25 diesel bellhousing bolts, spent ages hunting for some good length bolts to use, now its sat in place ive been able to get measurements for the n/s mount, so tomorrow i can get the metal and make that, then will make a copy of the o/s one, but will make sure i have plenty of clearance for the oil cooler pipes, i took the loom out of the Golf, after the kids are in bed i will sit down, open the loom up and remove everything i dont need, the loom has all the wiring for the horns, lights, wipers and fogs, once ive got that out there isnt much left to the loom, off the top of my head there is
starter
alt
oil
water
glow plugs, but not much else, a lot is contained between the ECU and loom, but doesnt go anywhere near being connected to the bus, because ive got the mounts to FAB still i havent touched the coolant pipes, mainly because i want the engine sat right first and go from there, ive had a thought on the exhaust, now we all know the smoother the route of the exhaust the better, so with that in mind ive decided my route will be down from the turbo, under the gearbox to the back box that will exit on the o/s 2 very gentle bends, a couple of hours with hacksaw and mig will have it sorted, right here are some updated pics

Image
Image
Image
Image
Image

i cant get over how much space there is around the engine, at the belt end there is still plenty of room to work, im a little gutted as the rain has stopped and sun is coming thro (wish id stayed a little longer at mums to get more done :cry: )
1988 Matt Black, T25 caravelle, Living the dream
Wanted diesel sump and oil pick up PM me if you can help
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Our camper build

Postby 16vmini » 05 Jun 2012, 18:12

Looking good.

With the exhaust yes smoother is good. But I would not worry to much. Just get it on the road. Exhaust is an ideal thing to re do later

Have you re- indexed turbo ? Assume you will need to ?
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Re: Our camper build

Postby max and caddy » 05 Jun 2012, 18:26

i would find the diesel water pipes if i were you...and turbo doesnt need to be re indexed no..but how do plan on intercooling it?
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Re: Our camper build

Postby max and caddy » 05 Jun 2012, 18:29

And....what are you planning to use for the n/s engine mounting bracket?
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Re: Our camper build

Postby 16vmini » 05 Jun 2012, 18:30

max and caddy wrote:And....what are you planning to use for the n/s engine mounting bracket?


nice bit of CDS would make a good mount i reckon , or some nice THICK box section

Matt
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Our camper build

Postby 16vmini » 05 Jun 2012, 18:45

Ps. Someone said use a passat box ? That would mean mounting engine transversely ? Would it fit ?

Matt
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Re: Our camper build

Postby ninja.turtle007 » 05 Jun 2012, 18:54

16vmini wrote:Ps. Someone said use a passat box ? That would mean mounting engine transversely ? Would it fit ?

Matt



There has been loads of talking about flipping a passat box, but has anyone actually done it yet?
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