VW T4 Forum - VW T5 Forum banner

1 - 20 of 34 Posts

·
Expert Campervan Converters
Joined
·
38 Posts
Discussion Starter #1 (Edited)
Hi Guys!

Just wanted to share with you all our T5 Pickup build !

We are going to be posting it step by step on this thread and also onto our blog page of our website.

So if your interested on how we turned this commercial T5 dropside into a stunning show vehicle, please watch this space!


Type "camperversions" into your search engine to find us, like us on facebook or follow us on twitter.


https://www.facebook.com/Camperversions

https://twitter.com/camper_versions


There's also our youtube channel you can visit and subscribe to for an uptodate video blog. We will be posting links to it as we go. https://www.youtube.com/channel/UCRO7t7gIdetG37SJTG3zs6Q.



Basically this all came about because we had this great idea that turned into 5 more great ideas.

I had seen previous twin cab conversions, with a small tub, but no single cab's that had a tub the size of a van!


We needed alot of space for what we wanted to create so off to find a decent single cab dropside and a LWB T5 bodyshell.....
 

·
Expert Campervan Converters
Joined
·
38 Posts
Discussion Starter #2
So we managed to find a single cab VW T5 dropside pickup that we bought from South Wales that was in decent condition.

Dint in the bonnet that the seller hadn't told us about! Good job we will be giving the front end a facelift and can just scrap this bonnet.


Hopefully when we are done with it you won't be able to recognise it.
 

Attachments

·
Expert Campervan Converters
Joined
·
38 Posts
Discussion Starter #3
So the next thing to get was a T5 body shell.

I had measured from the centre of the wheel arches to the back of the cab and figured that a LWB would be better purchase than a SWB, as we would have more shell than what we needed, rather than a SWB which would be just abit short.

The ease of the internet and I had purchased a body shell with a few bits and pieces still attached (these bits and pieces are available in our ebay shop! it was a 2013 plate, had a good condition steering wheel and clutch pedal, shocks, springs, exhaust, fuel tank to name but a few things!


Just waiting on the delivery...
 

·
Expert Campervan Converters
Joined
·
38 Posts
Discussion Starter #6 (Edited)
I thought the body shell would be a great way to teach our apprentices cutting out windows and cutting out poptops, as they can learn from their own mistakes without the costly repair bill if something goes wrong.


So we let the apprentices take the lead and fully fitted a poptop to it.

As they have helped out on many other roofs they only needed minimal guidance, mainly with the measurements.


Here's the result (shame it has to all come off, they did an excellent job!)
 

Attachments

·
Expert Campervan Converters
Joined
·
38 Posts
Discussion Starter #7
Once the poptop was checked over for the fit, it was removed. A job well done! An excellent learning experience for our apprentices, I have just bought another T5 bodyshell for them to practice again before they carry out the real thing on one of our own vans.


The apprentices took turns in cutting out windows, again a job which they were familiar with but needed the hands on experience, this experience came with alot less pressure with it being a test rig!


Once the windows came out, we welded in some steel cross braces, so that when we start chopping the bits off that won't be used for the T5 pickup conversion, it won't twist or bend, it will stay strong and square.
 

Attachments

·
Expert Campervan Converters
Joined
·
38 Posts
Discussion Starter #8
Now the T5 pickup’s off to Dave at Accrington beetles and campers!

It’s arrived at his workshop on our trailer we had been using to push it around the workshop.

Dave has a plasma cutter and so got straight on with cutting out everything that wouldn’t be used in the build.

Straight off with the roof first.
 

Attachments

·
Expert Campervan Converters
Joined
·
38 Posts
Discussion Starter #9
The cab's come off next, some serious weight it that!
 

Attachments

·
Expert Campervan Converters
Joined
·
38 Posts
Discussion Starter #10
Next thing is to strip out the dropside from the T5 pickup, so that we can measure what off the bodyshell needs to be cut out, particularly the floor, so that the bodyshell can be fit over the original chassis of the pickup.
 

Attachments

·
Expert Campervan Converters
Joined
·
38 Posts
Discussion Starter #11
Soon as the dropside was off we could see roughly what needed to come out of the bodyshell floor, so we made some measurements and started cutting.

After the first round of cutting, the bodyshell was positioned in place on the rear of the pickup.

Still more to cut out!

We didn’t want to lose more of the floor than what we had to and wanted the wheel arches to line up exactly with the wheels, so taking a bit off at a time we painstaking had the bodyshell on and off the pickup several times, taking out the main cross beams.
 

Attachments

·
Expert Campervan Converters
Joined
·
38 Posts
Discussion Starter #14
Finally, after small gains the T5 bodyshell has been cut and sits exactly where its suppose to, +/- a few mil either side. – Definitely needed the strengthening braces in!
 

Attachments

·
Expert Campervan Converters
Joined
·
38 Posts
Discussion Starter #15
Straight onto welding the bodyshell in place today with braces being fit into the floor and sides that will have steel panels lining them.
 

Attachments

·
Expert Campervan Converters
Joined
·
38 Posts
Discussion Starter #16
There’s a big dent in the bonnet, so really its only logical to facelift it. I’d seen these great looking bumpers on German eBay which is great for euro parts, helps if you speak Deutsch though.
The bumper is on its way, along with the Golf GTi styled headlights, the “sharkfin” style and a new sportline front grill.

Might as well change the wing rather than repairing, only £60 delivered from carpartsdirect.
 

Attachments

·
Expert Campervan Converters
Joined
·
38 Posts
Discussion Starter #17
A sliding door was bought along with a trim panel that covers the sliding door rail that will be welded in place and filled with filler and sanded down to look like a solid panel. The paint has to come of first were it will be welded to the cab and T5 bodyshell.
 

Attachments

·
Expert Campervan Converters
Joined
·
38 Posts
Discussion Starter #20
Me and Dave both agreed the floor would benefit from only a small distance between the braces, so in goes all the floor braces ready to be lined in sheet steel.

Quick test fit of the sportline rear lights, wiring pins to change around as usual.

Rear bumper fitted also
 

Attachments

1 - 20 of 34 Posts
Top