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Orion's ex-AA T5.1 Swamper Build - Team Yellow!

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31K views 228 replies 34 participants last post by  suty455  
#1 · (Edited)
Hi All. I thought I might do a build thread about my Swamper styled 2015 reg T5.1 T32 140 after a year of fettling and tweaking.

I love reading other folk’s posts and build threads and have found some really useful help, ideas and inspiration so I hope this of interest to others.

So in September 2021 I sold my LWB T5.1 180 BTDi Caravelle and became “vanless” for a few weeks while I hunted for a new project.

It’s surprising how bereft you feel with no van on the drive.

I knew I wanted a reasonably newish T5.1 (or maybe T6), ideally SWB (LWB was a bit big for the driveway ).
Prefered 6 speed ,140, tailgate and air-con. I had a budget anywhere from £15K to £25K depending on the van and work required.

I found ( and then kept coming back to ) a yellow ex-AA 2015 T5.1 on eBay that was fairly local ( only an hour away ), a reasonable price and had a decent semi converted interior with R&R bed although still a hardtop. It had 2 x side windows fitted but no rear tailgate window.

This appealed on a number of counts. It ticked the tailgate, air-con, 6 speed, 140 boxes etc but I also loved the yellow colour!

Having most of the interior work done would save me a lot of time and money but also still give me the flexibility of adding my own touches as well as adding some of the major stuff like a pop top.

I could see in the advert images that it had a quality interior including RIB seat, furniture from Camper Worx in a Vohringer blue grey metallic finish, a solid composite worktop with an interesting radius fridge step out. It looked to have some nice black alloys which turned out to be nearly new Oz 18"'s.

Appliances already fitted were a 12v JustKampers fridge and Dometic 9222 combi sink / hob. It also had a full set of decent internal silver screens, a nice bonus.

The van had a full AA service history up to 90K as well as more recent entries including a cambelt and pump change.
Current mileage advertised was around 110K.

So quickly booked a trip to view, met the nice young guy selling it, had a test and inspection, did the usual checks, bit of a haggle, handshake and bought including a full tank of fuel, screens and an unused matching table, rail and folding leg.

Happy with that as it left me with around £6 to £7K in the kitty to complete the van to my liking, possibly more if required.

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I had a list to sort out from my inspection:

The front driver seat was a bit worn and needed new foam, cab USB wasn't working , the engine warning light was coming on intermittently.

Tow bar not working, a couple of very small dinks and chips, rear bumper had a "lump" under the tailgate.

The roof still had the GPS and aerials attached plus the (supposedly) plugged holes from the AA lighting bar.

The Sargent K115A electrics just needed the external hook up sorting.

But, fundamentally, nothing major so time to crack on.

I had decided ,virtually from the moment I saw it, that the final outcome was going to be more of a Swamper style than lowered "lean ‘n’ mean".

I had downloaded loads of Swamper van images off the Net as inspiration and really like that style of van.

First jobs were some wing decals, black sequential side indicators and wind deflectors.

Big fan of deflectors , even have them on my little Kia Picanto daily now !


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#113 ·
Gone from cool to ice cool there mate, easily one of my favourites on here (y)

Think my suspension is feeling tired, 110k on the clock and I'm pretty sure they are the original parts. Just got to decide what to go for. Some research on the cards me thinks.

Cracking backdrop too 👌
 
#116 ·
Gone from cool to ice cool there mate, easily one of my favourites on here (y)
Think my suspension is feeling tired, 110k on the clock and I'm pretty sure they are the original parts. Just got to decide what to go for. Some research on the cards me thinks.
Cracking backdrop too 👌
Cheers Pete. (y)

My mileage is very similar ( around 112K ) and last few MOT's the shocks were on the advisories.

I reckon they were originals and the A.A probably gave them a bit of stick over the years

That's why I bit the bullet and emptied the wallet....

( Backdrop: was just a glimpse of Goyt Valley between Whaley Bridge and Buxton. Nice spot for a walk or bike ride )

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#115 ·
Cheers mate. Yes, the SoLow BIG-H's are distributed exclusively by THQ ( I found a 5% off code too which was handy..)

 
#119 ·
Next job: adding A-Pillar grab handles. No idea why these aren't standard on all Transporters?

The brackets simply screw into the existing holes so are easy.

The A-pillar trims were not fun as they didn't have the drill guides on the rear. Very, very tricky to get lined up.

Cocked up a bit on the LH one first and drilled holes slightly out of line so may need a new trim if I come to sell. I can live with it for now.

Anyway, done now and much easier getting in and out of the van now especially on the lifted suspension.

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And no help at all today from Enzo, the lazy van cat.

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#120 ·
Thats weird mine didnt have them but it did have the indicators where the holes should be on the trims, makes a huge difference as well (for the shortass wife that is!) was round your neck of the woods today at the Dub show in Derbyshire though you might have been there, been looking at lots of sprinters now hunting seriously
 
#121 ·
That's weird mine didn't have them but it did have the indicators where the holes should be on the trims, makes a huge difference as well (for the shortass wife that is!) was round your neck of the woods today at the Dub show in Derbyshire though you might have been there, been looking at lots of sprinters now hunting seriously
Yep, that was the problem for me, no "cloud" indicators to the rear.

Really odd how some have them and some don't. Still miffed I cocked up the LH holes.

Derbyshire Dubs is not far from me at all. If I didn't have so much on and the fact we are camping next week I would have gone.

Hope you had a good day, the weather is fantastic for a change.
 
#123 ·
Be very, very careful when fitting them if you haven't got the "guides" on the back of your A trims! Fingers crossed yours has them.

There is no way to know where to drill without them. I thought I had it with the old "blu-tac" hack but was still out, very annoying.

A stepped drill bit is also very useful as the holes are surprisingly large. A bit too large on my L.H trim now... :D
 
#131 ·
Have a search around if you're gonna buy a pair , can be had from chilli jam vans for £142 or travelinlite for £140 ;) .

As for fitting i fixed the bracket on first made a bolt with the head ground to a point to make a little indent in the back of the trim . This gives you the exact centre of each bolt hole.
As Orion said these holes are bigger than you think and i still faffed about trying everything ten times and carefully removing a bit more plastic each time to make sure theyre right.
If all trims came pre-marked it would be soo much easier 🙃
 
#136 ·
Finally got around to installing the Renogy 200w solar panel I bought last Black Friday!

I first sprayed in AA yellow the top grey plastic halves of the 2 x single cable Scanstrut cable seals just to blend them in a bit on the pop top roof


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I cleaned the roof thoroughly and attached the solar panel with 4 x strips of 3M tape.

I then fitted the junction box gaskets in place and drilled through the pop top for the solar cables.

The next step was re-fitting MC4 connectors then connecting them to the corresponding MC4 cables I had previously brought up from my Victron MPPT controller , across the ceiling space and out through the roof into the void between the rear of the canvas and pop top hinges.

I then checked my phone's Victron App to ensure the panel was outputting to the controller which thankfully showed it was working perfectly.

Nice to know we now have some off grid solar power to keep the battery topped up.

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#139 ·
It was a bit late in the day and the sun was facing away from my angled pop top when I fired up the app but I think it was showing about 28 to 30 watts.

I would expect more when positioned more favourably and a better time of day. I'll do a few checks as I go along.

It's mainly for topping up the battery to save me plugging in EHU at home and when we are off grid at festivals and using the van fridge for extra beer :D

We already have a big fridge and power pack with solar setup for the awning so it's backup really.

BTW, I also fitted a solar isolator box following advice on here from you guys before the MPPT.

 
#140 · (Edited)
Onto the next job of fitting the new fake rear quarter windows to replace the plastic swamper grilles.

Not a difficult job especially after watching the THQ fitting vid on YouTube.

Before ( rear swamper grilles removed )

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With primer on. Note small gap at base to allow any condensation behind window to disperse.

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Glass prepped and primed then add a good bead of adhesive to van panel primer line and stick on!

Note the rubber strip stuck to the edge. This is essential as it help hide the joint line of paint showing between the windows.

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Done. Really pleased with how these look compared to the "empty " panels.

They are slightly darker than the existing windows because they are 100% blackout.

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#144 ·
Whats next ?
Bench seat swivel plate. Can't decide on simple swivel or extend into the back style like MS Craft or Rusty Lee.

If I use the the extending one I can reach the table. But we really never use the clip on table, like ever...

Also it swivels so you sit and look out of the sliding door. But does ANYONE do this apart from in Blog posts...?

So I think I prefer the fixed swivel and maybe a small table on the B-pillar support.

Interested in anyone's views on this?
 
#145 ·
Vans looking good.
I've got a standard swivel plate on double passenger seat. Quite snug to turn it, have to drop the handbrake but works well and does a good job. When turned it can be pushed back a little or pulled forward a little. I don't have a table on the pillar as it's a snug turn on the seat. Just use the table off the main cupboards middle of van.
 
#148 · (Edited)
Well I finally got round to getting the Thule BackUp Box sprayed to match the van.

Yes, I know it now looks like a yellow council "GRIT" box but it looks better than standard Thule Grey IMO!

Maybe I could earn some beer money in winter gritting other folk's driveways, hmmmm.......:unsure:

( I do have a black VW decal on order to tie it into the rear van badge. )

Problem is I will have to sell it with the van now!

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#153 ·
I really did consider that, would be a laugh. :D

Joking apart a real GRIT bin is not that expensive. I could have just bought one in the first place.