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My t5.1 shuttle conversion

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22K views 78 replies 14 participants last post by  Mrfixit  
#1 ·
Hi, after spending a lot of time researching and viewing this forum for info and advice I finally think I have something to share. I just hope I get this post right: I had spent a long time searching for a van to use for work and leisure, I almost gave up after looking at loads of vans mostly were overpriced and in poor condition. Anyway, I finally bought a silver T5.1 shuttle from a really nice guy who used it in his travel firm. High miles but well looked after. It had a few marks on the body, but apart from that it was in really good condition and the price was right!
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The first thing I did was to remove the rear passenger seats and replace them with a California seat/bed on rails.
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You can see I kept the original interior trim but have replaced the carpet with a rubber floor, this because I wanted to utilise the window blinds built into the trim and save the cost of rebuilding the interior. I have put silent coat and insulation on the panels behind the trim and under the floor, I’ve also put a layer of under tile insulation directly under the rubber floor covering, the result is a bit like cushion flooring. Why a rubber floor? It’s easy to clean!
I will continue a bit more hopefully tomorrow.
 
#36 ·
As far as I am aware, (and I am happy to have this corrected!), a Shuttle is a Transporter - but specified primarily to carry passengers - up to 8 in my version. Another difference (in the UK) are that most Transporter ‘vans’ are considered commercial vehicles with different tax bands and have limitations regarding maximum road speeds. DVLA class Shuttles as cars. There are other versions of Transporters. I think there are sections on the forum with info about other versions.
 
#39 ·
So, when I got the van, there was minor damage to the bodywork. Originally I was going to repair it myself until I noticed that some of the doors were slightly different shades of silver to the main body colour. So I decided to get it sprayed at a body shop and go for something different - two tone Red and Silver. I also picked up a set of standard 16” VW alloy wheels which had brand new tyres on them that were going cheap. I needed to replace two tyres on the van, but when I saw that the alloys came with brand new tyres I decided to get them as it was cheaper than the cost of replacing the tyres. I had the alloys powder coated in gloss black and whilst they ain’t anything special they will do until I get an upgrade.
I have plans to tweak the suspension, sort out an awning, finish off some internal sound insulation work, maybe have some work done on the engine.................
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#48 ·
I used the live feeds under the passenger seat to power our seats .
Theyre permanent live and you can just populate the fuse holder thats already conviently there
Yes, I thought of that and thanks for your suggestion, but even though it’s unlikely I would ever leave them switched on, I’d rather go through a switched live....cos I’m easily distracted! Besides, I’ve now run the wiring to the fuse box.
 
#50 ·
Went for an mtb ride yesterday eve, most of the ride was on exposed hillsides and moorland where it was very windy, the air temp was about 12 deg, but with windchill it felt a lot colder! Towards the end of the 2 hr ride it rained, wet n high wind = very cold Mrfixit, by the time I got back to the van I was feeling Baltic - my hands were so cold I could hardly move my fingers - them heated seats were brill!
Also, I’ve put some footwell lights and a glovebox light in. I got a bit confused with the instructions for the footwell lights, directs were to connect to black/red and red/brown wires in a white plug located at the end of the dash on the passenger side. My plug did’nt have a red/brown wire, black/red - yes and purple/yellow and a brown/cream, so I connected to the brown/cream.
Glovebox n footwell lights;
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#56 ·
Felt so good to dry off and put dry cloths on.
So, you are spending so much on your van that you are reduced to just wearing cloths?Visions of some form of Tarzan like attire come to mind 😆
Some time next week I hope to insulate the roof. Tried to insulate the sliding doors but again I could not remove the trim, the trim, and the connectors just keep stretching and would not part from the door! I may have to remove the door just to remove the trim 😫😤😖
 
#63 ·
Just had cam belt and water pump changed, which was booked for early March, but the workshop closed due to covid 😫 also decided to have brake/clutch fluid changed at the same time - it was looking quite dark and I don’t have any history of when it was last changed. I would have done this myself but could not see where the bleed screw is for the clutch and, my wheels had ‘glued’ themselves to the hubs, I guess because the powder coat on the wheels had melted due to heat generated during driving? And, a very nice man from Auto Windscreens came and replaced the damaged windscreen. He used a clever gadget involving some very thin wire that did a clean cut through the adhesive between the body and the screen without touching the paint!
 
#66 ·
Changing from 1st to 2nd gear and 2nd to 3rd has been becoming increasingly difficult, so I decided to see if adjusting the gear selector cables would improve matters. I thought of using the method described in the Haynes manual but some of the description was a bit vague and, I did not have the special gauge tool, then I came across this: Definitive guide to adjusting gear linkages on a Vw T5. when I tried it, the locking mechanism on the gear selector cable end piece would not slide smoothly down or stay in the unlocked position and when I could get it to move, it just kept pushing the cable down, then the mechanism would disconnect from the cable and pop back up to the locked position 🤬 I also saw this: 6 speed won't go from 3rd to 2nd so not wanting to make things worse for myself I bought the tool and eventually managed to adjust the cables; but I had to get my missus to hold the gear box selector lever in 2nd gear while I wrestled with the non compliment cable end piece to ensure it would allow the cable to stay in the correct position, lock solidly onto it and not pop back off it. Whilst better than before, changing from 1st gear to 2nd still ain’t brlll 🙁 Any ideas?
 
#69 ·
Just a quick update. Had the old rusty exhaust finally replaced with a direct fit stainless steel 2.5” single exit exhaust from Cybox in Bromborough on the Wirral, (across the River Mersey from Liverpool, for those who may not know where the Wirral is). Mark promptly answered my email query and when I mentioned this forum he gave me a bit of discount off the advertised price and fitted it for what it would have cost to post it. I wanted a quiet exhaust and it is!
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So that’s some good news, bad news is my air con is leaking 😫. I took the undertrays off to check the pipes and found what appears to be several leaks - there is dye in the system to help detect the leaks. It seems that the gas is leaking from where the rubber pipes connect to the metal pipes, there may be a leak on the rubber pipe that runs around the front of the rear wheel arch 🤔. There are signs of rubbing on the wheel arch cover and the rubber pipes have what appears to be dye on them. What don’t help is that the wax oil which has been sprayed on the van also reacts to the uv light which is making it a bit awkward to work out which is the dye or the wax oil 😒 Anyway, I will be visiting my local very friendly local garage for their opinion. Looking at the way some of the hoses are connected to the metal pipes it looks like I may have to replace rather than repair ☹
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