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Discussion Starter #1 (Edited)
my T4 conversion project - budget challenge (pics added)

Hi all,

happy to say i am now the proud owner of a 1997 swb 1.9td 800 special.

so i've set myself a challenge - if interested in seeing what that is then visit my site

got most of the bits & bobs i need for my conversion part from alloys. anyway i've put up a web site for those who are interested in my conversion on a budget process, including pics & thoughts as it goes along!

LINK to my site: t4project site

be interested in your comments
 

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Discussion Starter #3
thanks for checking it out.

it came from [derby university] and was used as a cleaning van for nine years. the green is the university colour.

think i'll take it back to white though! then i can join the white van crew ;)
 

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Discussion Starter #5
will do, white van all the way.

by the way i used to live in colchester! great scene down that end but sadly no surf:(
 

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Discussion Starter #6
thought i'd post some pics of work so far.

i haven't done much yet cause i pulled my back out trying to lower the van LOL:

there i was with the van jacked up, one wheel off and me lying flat on the floor in agony - should have seen my wifes face :eek: she thought i was dead!


about the van:

1997 SWB 1.9td 800 special
bought from Derby University [that why it has a green roof and bonnet], where it served them as a cleaning van nearly all its life, so its in pretty good shape. came with full service history and runs sweetly.

so anyway a few pics. i'll be back on it this week and post some more

let e know what you think so far.


1. van as i bought it










2. had windows put in side - now ready to tint [will update soon]




3. cab - as bought




4. interior - rear tailgate view + removed the 1\2 bulkhead










4.1 interior - insulation step [1] carpet underlay






4.1.1 interior - insulation step [2] 25mm foam






so there it is, not done too much at the moment but getting there!
 

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Discussion Starter #8
did the tailgate panel today

1. tools for the template



2. preparing the template



3. template sketched up



4. template cutout



5. template cutout checked for fit



6. also made template so i know where to put speakers



7. template ready and checked



8. template drawn on 6mm exterior ply



9. tools to cut out panel



10. panel cut



11. getting ready for the carpet now



12. carpet cut and ready to get stuck + tools for the job



13. carpet stuck to panel



14. know just have to fit the speakers



15. and there you go



just need longer screws for the handle and its done. little cutout for the inside door catch too.

16. also did the headlining



until the next installment...
 

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Discussion Starter #10
hey m8.

just got finished looking at your van, very nice indeed - lovely workmanship.

erm yeah, so far i'm on budget and time...but i know how these things go. i think if anything will blow it, it would be the wheels. plus every time i start a job i find that i need to buy something else that i seem to be missing.

we will see. anyway tomorrow is dumping day!

 

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Discussion Starter #11
today i found a bargain in halfords. a pair of poineer speakers for £10 reduced down from £40. so i put them in the van

1. my bargain speakers



2. prep time - dash speaker



3. removing the speaker cover



4. taking out the old dash speaker



5. the speakers in comparison - old & new




6. tools for the job



7. preparing the wires









8. new speaker in - prepping the holes



9. new speaker in - screwed in



10. job done - repeat on the other side






lowering the van tomorrow!!!!
 

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Discussion Starter #12
just thinking about the exterior and wondered what to do with the tailgate??

heres some ideas

1. original
2. no name tag
3. no vw badge
4. naked [including no wiper]

interested to know what your thoughts are...

 

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Discussion Starter #15
yeah thats the way i'm leaning for sure. we will see.

so today nightmare time lowering the van. so here are the pics so far:

1. tools ready to lower rear [60mm lowering kit from t4srus]



2.rear prep for lowering





3. spring off



so got to take the last bolt out that holds the shock in place at the top and the thing wouldn't come. needed a new socket to fit just right...

4. van so far after i lowered the left torsion bar [right would not come so had to buy 27mm spanner]



5. tools ready to lower front



6. wheel off prep for taking shock off & lowering









OK, so now i'm just really annoyed. the second bolt to the right that holds the shock plate in [at the top of shock] well, it just kept spinning & spinning. i couldn't get any purse on the thin bolt head at the top [anyone else had the same issue that could help give some pointers here would be my hero]. so stuck it all back on and went underneath.

7. torsion bars



8. with my newly acquired 27mm spanner [anyone need to borrow it, your welcome!]



9. lowered



so i still have some tweaking todo with the rake etc but want the shocks on first. plus i want to let it settle down just a bit. thing is i still have like 45mm on the torsion threads togo...so when i eventually get those bolts lose [again any tips please] i'll wack the shocks on and tweak some. when i was playing with the torsion nuts i did feel a twang of just dump it to the floor should'a got the 85mm kit lol. still the things empty right now so need to test the water and be sensible...

also the thing sits slightly higher on the right [even @ back + the torsion nut was lower on the right before i even started?]

appreciate comments and tips about my woes...cheers

getting ready to fit the interior...

 

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this is becoming a real good build thread, good job T:

Roof lining - you should think about doing the metal work as well, you may already be doing so, but i noticed you've put up your roof lining already and i know it a pain to put up. I under lapped the carpet that covers the metal.

Rear view - i see the appeal to the clean rear end ( i have a new debadged front grill) but i'm proud its a VW and still wanna wear the badge with pride, so for me the rear badge stays :D

T:
 
W

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Good thread, matches almost exactly the mods I'm doing. So far I have:

Lowered it 60mm,
Fitted 16" alloys ( going for 18" asap)
Put a gear stick extension in,
Fitted two Recaro seats from a Mercedes SLK,
Removed the half bulkhead,
Replaced the dash speakers with 2 Pioneer 10cm ones,
Sound proofed with flashing tape and a bubble wrap moisture barrier before adding Rockwool.
Now I am carpeting the boards and walls and have the head liner ready to fit.

Then I will fit a VSR and utility battery, along with a 12v/240v system.

Once this is done I have a reversing sensor to fit, floor to insulate and reboard. I also intend fitting 3 amps, two 12"subs, and 4 other speakers along with a new head unit and 10 CD autochanger and have started laying the cables as I board out.

And finally maybe an XBOX and big telly?A:

Oh and then carpet the cockpit and refurb the dash.... it never ends... I:



Oh and then the outside..... Rustoleum I hear you ask?
 

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Discussion Starter #18
this is becoming a real good build thread, good job T:

Roof lining

Rear view

T:

hey thanks for your support on my thread. hey you know i totally forgot about the roof insulation, so yesterday i took down the panels ready for insulation today. nice one.

still undecided about the rear, but i get you point about the badge and all :ILU:


Good thread, matches almost exactly the mods I'm doing.

Oh and then the outside..... Rustoleum I hear you ask?
thanks bro. man it's so much work, seems like your going to town too. i'd be interested in seeing your progression. do you have a build thread or some pics i could see?

i've been busy but real tired so i haven't updated for a time so...I:
 

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Discussion Starter #19
OK. the next installment. ply panels, wiring & some carpeting...

sliding door panel:

1. took the old panel to make sure it fit OK [it was off a bit]



2. offered up the panel and marked out a new adjusted template on the ply





3. cut the sliding door panel [including tools]



4. ready for carpet










OK. side rear panels. the big ones and very little template to go by... bring on the measuring skills :confused:

1. rear quarters... this was the only template i had to go by and my measurement card!





2. after cutting out from my measurements



3. gulp, lets see if it fits?







not bad. happy with that. other side to do now, which is slightly different.

1. basically doing the same with some adjustments...it turned out just right too A:





2. next i did the speakers [including tools for the job]



so all the panels are cut now and ready for carpet and fitting [yeah]


wiring next

i want to put some 12v hook-ups next to the kids seats so they can play ds on the long trips and so i have some minimal power in the van

1. this is where i want to put them



2. got template ready & cut out





3. holes cut in place and ready for wires



4. fitted [tools for the job]









5. check to see if they work?





6. carpet on ready for final fit



7. job done






there was a nasty hole in one of my dash bits so...

8. wired a switch in so i could control the power [and the kids Rasp:]












So the next job was to run the wring to the dash for the amp [going under the drivers seat]

1. stripped out the cab



2. rubber floor needed a good wash too



so i got the wife involved with some technical work LOL:





3. wiring ready to fit



4. getting the amp power cable through to the engine bay









5. laying the rest of the wires & some protection





well thats it for now. will press on and update soon... more interior to come
 
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