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Old 19-04-10, 23:25
StewRat StewRat is offline
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Default Transformer. T5.1 LWB 104PS DSG

Collected it last Thursday.

This was originally going to be a kombi but VW having lotsa probs getting type approval for the version I wanted, yadda yadda so I ordered the panel van and will get windows and seats added in a couple of weeks.

Short/medium term plan is for this to be company car, camping and MTB carrier, and then all being well will get converted into a camper in a couple of years.

So work done so far over the weekend, starting with the "before" pics ...



Still smile every time I see it.



Not totally "before" as i'd already removed the lashing rings and covered the holes with flashing tape before I remembered.

Don't reckon the floor is a major source of noise, but decided to hedge my bets with some flashing atpe on the wider unribbed sections of the floor ...



... with some ply on top to bring those sections up to the level of the surrounding ribs.



Then a layer of bubble foil insulation - not a very effective insulator but again seemed to be "better safe than sorry".



Then things start to get a bit tricky.

I ordered a lining kit from plyliningservices.co.uk as it seemd a better starting place than making my own templates etc. The floor is 9mm, but a) it comes in 3 pieces and b) it has cut-outs for the lashing points (which I am not using).

So first off I had to patch the holes, including patches on the underside to make them stronger.

And then I wasn't very happy with the solidity and fit of the 3 panels ...


... so I decided to plate it with hardboard panels glued over it. This made a big difference.



There's a funny effect on thsi pic that makes the floor look like it bulges - it doesnt!

And that's about it so far - have got the vinyl laid but not fully trimmed off, and have built an internal bike carrier from PVC pipe, pics to follow.
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  #2  
Old 19-04-10, 23:29
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JIMMYJAMES JIMMYJAMES is offline
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Default Re: Transformer. T5.1 LWB 104PS DSG

Literally a new conversion, good progress so far bud
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  #3  
Old 21-04-10, 08:37
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exocet exocet is offline
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Default Re: Transformer. T5.1 LWB 104PS DSG

Stew,
If you are going to get rear seats fitted I would check with the guys that are doing the conversion for you if it's okay to go ahead with the floor finish, they had to remove the ply on mine, they were very specific on the thickness, If I can remember well, they wanted a 15mm ply? but not 100% sure, then again my seats where on a rail, yours may be a different system, maybe safe bet to check before you apply your lino! good luck with th conversion, red 5.1 looks good.
Exo
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  #4  
Old 21-04-10, 10:26
StewRat StewRat is offline
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Default Re: Transformer. T5.1 LWB 104PS DSG

Cheers exocet for the warning

Seats and windows being done by Lakeland (not the kitchenware people) and I think they have a 3ft or so print out of email correspondence on the subject so far

Their view seems to be that its customer choice to put final layer on first or not depending on whether you want to be able to easily remove it later with seats in place or prefer to have the whole thing bolted togather by them.

My seats are going to be a 2+1 San Marco high back on quick release fittings, not rails. That may be the key point as I guess rails mean channelling through everything to fit them.
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Old 21-04-10, 10:34
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exocet exocet is offline
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Default Re: Transformer. T5.1 LWB 104PS DSG

Cool, I just thought to let you know in case you had to re do the job again later!
Nice one, good luck
Exo
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  #6  
Old 03-05-10, 21:48
StewRat StewRat is offline
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Default Re: Transformer. T5.1 LWB 104PS DSG

So now the vinyl - B&Q imitation checkerplate is down:



I have a treadplate to go across the back but I'm not fastening it all down until the middle seats are in - justr in case it all has to come back up again.

Of course now the floor is a good bit higher than it started - so the step insert needed modified to fit. Built up the level underneath for support, trimmed back some of the support waffles under the insert where it was now fouling on the new floor, and finally (can't really see it in the pic very well) shaped a piece of ply to fit under the now raised lip of the insert, and painted it black.



Again, it's all loose until the seats go in, but end result looks like this:



Then it was time to turn my hand to upholstery with the Graphite carpet from MegaVanMats.

Decided to do the tailgate first as a) it already had a trim insert that I used to fine tune the not perfectly shaped piece from the ply lining kit and b) it had no contact with the floor or sides that might change once seats and windows are in.

As well as tuning the shape a bit, I took off a few mm all round to compensate for the carpet thickness wrapped round the edge.

I am quite pleased with my first attempt - lots of tucks round the corners, then slice them off with a sharp blade and it all sits nice and flat on both sides.





When it came to fitting the panel, I realised there are already a lot of holes in the lip I'd be screwing into, so I marked suitable screw positions with tape round the edge of the area befor eoffering up the carpetted insert. Didn't want to screw through my panel only to find fresh air on the other side!

B&Q recycled plastic bottle insulation in the cavity, sealed with bubble foil and aluminium tape. Tip of the day for everyone with no fingernails: tear your aluminium tape rather than cut it - it's a lot easier to find a bit to peel back that way!



I used black No 6 3/4" self tapping screws from Namrick which worked out very well - I bought cups too but didnt use them. The screws will drill through the metal themselves, making it a fairly simple job to hold the panel in place and use a drill to screw through the panel and metal in one go with no pilot holes etc.

Screw them right in and they almost disappear into the carpet.


Last edited by StewRat; 03-05-10 at 21:50.
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  #7  
Old 07-05-10, 12:11
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Chris in Swansea Chris in Swansea is offline
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Default Re: Transformer. T5.1 LWB 104PS DSG

Loving the vinyl you have used!

What are your initial thoughts on the DSG?
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  #8  
Old 07-05-10, 14:12
StewRat StewRat is offline
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Default Re: Transformer. T5.1 LWB 104PS DSG

Quote:
Originally Posted by Chris in Swansea View Post
Loving the vinyl you have used!

What are your initial thoughts on the DSG?
DSG = all good.

I've come to this from a Citroen C4 Grand Picasso that had their equivalent (but with steering wheel paddles for the manual shifts).

DSG is much smoother than that - you don't notice most of the shifts and it seems to be pretty intelligent re speed, load etc.

Whacks you up through the gears for economy (55mph, 7th gear, 1500rpm) but happily drops you down a couple if you put the foot down.

Only annoyance is that they haven't made a true RHD version of it so all the gate letters are on the "other" side and as a beginner you have to peer round the stick to see them.
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Old 27-05-10, 13:47
StewRat StewRat is offline
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Default Re: Transformer. T5.1 LWB 104PS DSG

Got the seats and windows put in a couple of weeks ago by Lakeland Windscreens in Kendall

Two privacy glass fixed windows bonded in:





Nicely finished inside:



Tailgate glass tinted to match:



2+1 high back seats installed - they're pretty basic but they tone in nicely and have seat belts, which is all I need for their occasional use over the next couple of years:



Positioned carefully to ensure I can still get an MTB in lengthways behind them:



Haven't had a minute to myself since then, so no progress otherwise, but have high hopes for the next week or so (and my wife would like to get that ply and carpet out of the hallway).
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  #10  
Old 28-05-10, 09:36
StewRat StewRat is offline
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Default Re: Transformer. T5.1 LWB 104PS DSG

Did the slider door panel last night.

Don't know why I make things difficult for myself, but having seen the examples of VW logos raised under carpeted panels, I had the idea to set the logo into the panel for an embossed effect instead.

Traced an enlarged logo onto card and used it mark out the door panel. jigsawed out the circle bits I'm going to keep and glued a piece of hardboard to the back of the hole.

Then I traced the template back in to the hole and glued back the raised pieces in position.



I glued the carpet to the logo area first - very nerve wracking!!

I'd thought I'd be able to lay the carpet "loose" on the logo and work it into the areas - but the glue grabs too quickly and there was no slack, so it had to come back up and be done from the top down, working it into the grooves as tightly as I could with an assortment of tools - sturdy paint scraper, artist paintbrush handles, scissor handles etc etc.

I did end up with one crease in the flat below the logo - I think this may be unavoidable - and I'm not sure I did the best job of cutting it down/out. Hopefully a bit more brushing will hide the scar.



The effect is very subtle - perhaps too subtle for the effort! In certain light it stands out but otherwise is quite low key. Thicker ply (this is 6mm) would be more obvious, and I did consider adding depth behind but the panel is already going to be hard up against the door frame so that would push it out.



Trouble is - I now feel committed to doing another one in the opposite panel!
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