VW T4 Forum - VW T5 Forum banner

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

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.

Image


Image


Image


Image



Image


Image


Image


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 !


Image




Image




Image
 
#2 · (Edited)
Next job was to remove the front grille and badge and fit a de-badged version with yellow trims.

My other half really liked this saying "it looks less like an AA van now!" .

Then a new gear stick 6 speed knob and gaiter.

Went for a simple yellow stitch on black as I hadn't decided yet on what seat covers I was going to end up with so kept it subtle.


Image


Next job was fitting a Vankraft folding seat bracket to the double passenger seat.


I decided from the start to keep the double seat as we occasionally need to sit 3 in the front for IKEA runs, festivals and the like.

The storage space under the passenger was a novelty as well with my last two vans both having swivel singles to the front.

I couldn't fit a swivel double base yet as the tow bar electrics needed sorting and the module was under the passenger seat. I did remove some more AA wiring, fuse blocks and second battery fixing plate under the seat

I also made a ply insert from the Vankraft template which forms a simple seat when folded down and a solid surface to step up into a pop top if fitted.

Very pleased with the result as it makes a great “shelf” when working and really opens up the cab area when folded down.

The 10% extra reclining angle also makes the passenger seat a bit more comfortable as well.


Image





Image


I also bought some primed wing mirror covers and rear tailgate spoiler.

I removed the interior stereo and heater trim and the nearside and offside cab heater trims and sent the lot off to the spray shop for a nice few coats of AA Yellow.

While I had the dash apart, I took out the basic VW stereo, replaced the broken traction control button and removed a weird metal bracket that must have supported some AA gizmo.


Image



I rewired the dash USB that the AA seem to fit in all these vans ( changed to a twin version and piggybacked off fuse 19 )

I also added a 12v socket to the inside of the glove box ready for the reversing camera I planned to fit shortly.


Image



The engine warning light that came on intermittently was also diagnosed by my trusty local garage as a faulty EGR.

Turns out it was fairly new ( the guy who sold me the van said it had been replaced fairly recently on a service ) but almost certainly a no brand cheap make.

Swapped out for an OEM Pierburg one, job done. No more light since.

The spray shop sent me some images to show how things were going which I got a bit excited about. I hoped that these wouldn't look too O.T.T!


Image


Image


It was now December so I bought a new stereo off eBay as my Xmas present to myself ( any excuse for van stuff..).

I wanted a genuine VW for ease of wiring, but it had to have Bluetooth & Sat Nav so tracked down a mint RNS 315, duly delivered and simply fitted with plug and play.

Got an SD card off the Bay and updated the maps to 2021 full UK & Europe, nice! I also added a cheap Amazon GPS module behind the glove box, worked a treat.

With hindsight I should have changed the cab light and added the VW microphone for hands free which became a much later job.

I bought the same solar powered wireless reversing camera from Amazon I had fitted on my previous Caravelle as I was so pleased with it.


Fits neatly on the rear number plate with the camera at the top and the solar panel / battery and the LCD screen sits nicely on the cab top tray.

I drilled a hole for the monitor cable in the rear of the top tray and took it through the bulkhead to the 12v supply previously fitted in the glove box.

The remote on / off button is fixed to one of the dummy panels in the dash near to the steering wheel.


Image



Image