My T25 restoration

For documenting and technical details of T25 restorations and major repairs
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My T25 restoration

Postby mshaw1980 » 30 Apr 2017, 21:27

So as I have finally found out how to post pictures thought I would document the jobs undertaken on the T25 I bought back in Jul 2015. Wasn't an ideal start to the relationship as I went from the Isle of Man to collect it in Devon and 50 miles later oil buzzer goes due to a big end bearing which I found out later after tearing the engine apart. Luckily a week before I bought it I paid an extra £10 on my AA membership to give me relay back to the IOM. Best £10 I ever spent :D
So here she is

ImagePassenger step gone! by Mark Shaw, on Flickr
Last edited by mshaw1980 on 21 Jul 2017, 08:31, edited 3 times in total.
1987 VW T25: Subaru EJ20 using RJES parts (If it was meant to go fast it wouldn't be brick shaped!)
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Re: My T25 restoration

Postby mshaw1980 » 30 Apr 2017, 21:40

Rot in usual places but underneath is very solid
ImagePassenger step gone! by Mark Shaw, on Flickr

ImagePassenger step gone! by Mark Shaw, on Flickr

ImagePassenger step gone! by Mark Shaw, on Flickr

ImagePassenger step gone! by Mark Shaw, on Flickr
Last edited by mshaw1980 on 21 Jul 2017, 08:35, edited 1 time in total.
1987 VW T25: Subaru EJ20 using RJES parts (If it was meant to go fast it wouldn't be brick shaped!)
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Re: My T25 restoration

Postby mshaw1980 » 30 Apr 2017, 22:25

So engine removed:

ImagePassenger step gone! by Mark Shaw, on Flickr

As mentioned above, picture of the big end. Should be smooth and shiny...it's not and made the engine sound like pots and pans were being chucked around in the engine bay. Not impressed by this engine in terms of durability or power. Subaru engine will be nearly double the power of the carbed waterboxer 1.9 and vastly more reliable.

ImagePassenger step gone! by Mark Shaw, on Flickr
Last edited by mshaw1980 on 21 Jul 2017, 08:37, edited 1 time in total.
1987 VW T25: Subaru EJ20 using RJES parts (If it was meant to go fast it wouldn't be brick shaped!)
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Posts: 359
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Re: My T25 restoration

Postby mshaw1980 » 30 Apr 2017, 22:40

Bye bye waterboxer

ImagePassenger step gone! by Mark Shaw, on Flickr

Hello Subaru...

ImagePassenger step gone! by Mark Shaw, on Flickr

Engine cost £200 with all looms and ecu from an Impreza sport that had 88k miles with a knackered clutch. I changed the cambelt and water pump for peace of mind.

ImageIMAG2472 by Mark Shaw, on Flickr
Last edited by mshaw1980 on 21 Jul 2017, 08:40, edited 1 time in total.
1987 VW T25: Subaru EJ20 using RJES parts (If it was meant to go fast it wouldn't be brick shaped!)
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Re: My T25 restoration

Postby mshaw1980 » 01 May 2017, 20:27

Bit of vactan in the engine bay



Followed by a coat of rustoleum in the colour the exterior of the van

ImagePassenger step gone! by Mark Shaw, on Flickr

Trial fitted the metal behind the rear passenger light void whilst fitting a new rear arch panel.

ImageIMAG2472 by Mark Shaw, on Flickr
Last edited by mshaw1980 on 21 Jul 2017, 08:44, edited 1 time in total.
1987 VW T25: Subaru EJ20 using RJES parts (If it was meant to go fast it wouldn't be brick shaped!)
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Re: My T25 restoration

Postby bigbadbob76 » 01 May 2017, 21:01

May the fourth be with you (in a couple of days) Mshaw.
Gonna be watching this one, thanks for posting. :ok
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Re: My T25 restoration

Postby mshaw1980 » 04 May 2017, 21:36

So decided to tackle the crusty rear quarter and wheel arch

ImagePassenger step gone! by Mark Shaw, on Flickr

Not looking too healthy under the sliding door rail.

ImagePassenger step gone! by Mark Shaw, on Flickr

Cut open above rear jacking point

ImageIMAG2386 by Mark Shaw, on Flickr

Cut the sliding door rail off to reveal this...

ImageIMAG0007 (2017-07-08T07_57_25.000) by Mark Shaw, on Flickr

Bit more work to be done then :-(
Last edited by mshaw1980 on 21 Jul 2017, 09:20, edited 1 time in total.
1987 VW T25: Subaru EJ20 using RJES parts (If it was meant to go fast it wouldn't be brick shaped!)
mshaw1980
 
Posts: 359
Joined: 10 Aug 2015, 06:50
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Re: My T25 restoration

Postby mshaw1980 » 04 May 2017, 21:42

So had to cut out the rotten metal from under the sliding door rail. My van didnt look too bad when I bought it. Just shows you when you scratch the surface there is a lot of work to be done:

ImageCrusty jacking point by Mark Shaw, on Flickr

Cleaned up the metal ready to weld in the new panel, kindly supplied by Mick along with advice on how to realign the sliding door rail when complete. Then welded in the panel which is thicker steel than the original so hopefully wont corrode away when covered in zinc primer

ImageCrusty jacking point by Mark Shaw, on Flickr

Trial fitted the sliding door rail, held on with bolts which went through holes drilled through the panel into the van. Checked the door and it closed as it should, thanks Mick :ok

ImageCrusty jacking point by Mark Shaw, on Flickr

My 8 year old son was responsible for some of the cute graffiti before I was able to fit the rear quarter panel :-)
ImageCrusty jacking point by Mark Shaw, on Flickr
Last edited by mshaw1980 on 05 Mar 2018, 22:51, edited 3 times in total.
1987 VW T25: Subaru EJ20 using RJES parts (If it was meant to go fast it wouldn't be brick shaped!)
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Posts: 359
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Location: Peel, Isle of Man
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Re: My T25 restoration

Postby Ant-t » 10 May 2017, 23:50

Nice roof, makes me think about my bus mmmm :wink:
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Re: My T25 restoration

Postby mshaw1980 » 21 Jul 2017, 09:45

So I did repair the rear jack point similar to boatbuilders but forgot to take pics all through the process. This is a bit part way through...

ImageIMAG2463 by Mark Shaw, on Flickr

ImageIMAG2464_1 by Mark Shaw, on Flickr

I did clean all this up, welded in some new thick steel, vactaned and then but welded a new piece of steel over the hole. Honest :-)

Also had to repair the inner sill near the jacking point. Excuse the welding, this was quite difficult for me welding overhead when I am a novice

ImagePassenger step gone! by Mark Shaw, on Flickr
Last edited by mshaw1980 on 05 Mar 2018, 22:54, edited 1 time in total.
1987 VW T25: Subaru EJ20 using RJES parts (If it was meant to go fast it wouldn't be brick shaped!)
mshaw1980
 
Posts: 359
Joined: 10 Aug 2015, 06:50
Location: Peel, Isle of Man
80-90 Mem No: 14800

Re: My T25 restoration

Postby mshaw1980 » 21 Jul 2017, 09:49

Whilst the rear quarter was out the way thought I would take a look at the rear spring mount. When I took the spring out the central bobbin which keeps the spring from slipping out actually just fell off. New spring mount from brickwerks needed then. I did clean all this up and welded the new spring plate in so will get a picture of this when next under the van.

ImagePassenger step gone! by Mark Shaw, on Flickr
1987 VW T25: Subaru EJ20 using RJES parts (If it was meant to go fast it wouldn't be brick shaped!)
mshaw1980
 
Posts: 359
Joined: 10 Aug 2015, 06:50
Location: Peel, Isle of Man
80-90 Mem No: 14800

Re: My T25 restoration

Postby mshaw1980 » 21 Jul 2017, 10:05

So now was the time to get the new rear quarter on along with the lower rear corner and the piece just above as both were very rusty:

ImageCrusty jacking point by Mark Shaw, on Flickr

The lower rear corner took a lot of tweaking to get to fit adequately. Its not perfect but not far off. Happy with my work so far considering have never done any bodywork before.

As the top of the panel was spot welded to Mick's panel I took boatbuilders advice and used fibreglass filler to make it waterproof. Will put regular filler on top of that, sand down and then no one would ever know :-)

I also covered all the seams in vactan. Will also stick paint in to before using seam sealer so hopefully that will prevent future seam rot. I then coated all the inside of the arch with a few coats of tetrosyl underseal but I may actually also buy the brickwerks plastic wheel arch liners as that should definitely keep rust at bay then.
1987 VW T25: Subaru EJ20 using RJES parts (If it was meant to go fast it wouldn't be brick shaped!)
mshaw1980
 
Posts: 359
Joined: 10 Aug 2015, 06:50
Location: Peel, Isle of Man
80-90 Mem No: 14800

Re: My T25 restoration

Postby mshaw1980 » 21 Jul 2017, 10:14

So time to have a look at the front wheel arch and lower B post. My plan is to get all the metalwork done on one side then paint it in rustoleum. I can then reverse it out of my garage and do the same on the other side:

ImageCrusty jacking point by Mark Shaw, on Flickr

B post not looking too healthy with wheel arch removed

ImageCrusty jacking point by Mark Shaw, on Flickr

Front passenger step is a bit crusty and the seatbelt mounting so will have to change them whilst I am in there

ImageCrusty jacking point by Mark Shaw, on Flickr
1987 VW T25: Subaru EJ20 using RJES parts (If it was meant to go fast it wouldn't be brick shaped!)
mshaw1980
 
Posts: 359
Joined: 10 Aug 2015, 06:50
Location: Peel, Isle of Man
80-90 Mem No: 14800

Re: My T25 restoration

Postby mshaw1980 » 22 Sep 2017, 11:43

So I have rebuilt the bottom of the b post and got all this little lot in...
[url=https://flic.kr/p/Ymq31h]Image[/url
[url=https://flic.kr/p/YJY7We]Image[/url
[url=https://flic.kr/p/YXxGKH]Image[/url

The wheel arch and front step fits very well. They're one of the better repro panels from brickwerks. Once the b post was rebuilt, fitting the wheel front arch wasn't too tricky :ok
1987 VW T25: Subaru EJ20 using RJES parts (If it was meant to go fast it wouldn't be brick shaped!)
mshaw1980
 
Posts: 359
Joined: 10 Aug 2015, 06:50
Location: Peel, Isle of Man
80-90 Mem No: 14800

Re: My T25 restoration

Postby mshaw1980 » 27 Sep 2017, 21:14

So just need to finish sanding the filler, bit of primer and then I am ready for the first coat of rustoleum on this side of the van. Bottom of the van is going to be the same colour blue as the pop top and the white part of the van and wheels are going to be vw pastel white. Only got to do similar repairs on the other side of the van, front deformation panel, rear tailgate seal channel etc etc and Trigger the Transporter's bodywork will be more or less solid. Can then get stuck in to the interior. I am pleased with my bodywork progress. I am not quick but my welder friend has said I have done a good job. All a learning curve. Mechanical = easy. Bodywork = not easy

ImageNearly ready for paint on this side of the van :-) by Mark Shaw, on Flickr
1987 VW T25: Subaru EJ20 using RJES parts (If it was meant to go fast it wouldn't be brick shaped!)
mshaw1980
 
Posts: 359
Joined: 10 Aug 2015, 06:50
Location: Peel, Isle of Man
80-90 Mem No: 14800

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