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Thought i would get my build thread up on the forum as i have had it 2 years now.
Lots of pics, but probably a standard build.

I will Try and keep it organised with a 'contents', as per a couple of other threads.

History
Bought the T4 from ebay for £2100. It is a LWB 2001 with the 2.5 tdi and 88bhp.
It came with no history or even a logbook, i checked its history using the MOT website and HPI'd.
It looked a little worse for wear and drove terrible. Very slow and noisy.

Mechanical
I had the cambelt and tensioner, altenator and belt and crank pulley changed and blocked off the EGR.
It still ran slow so i put it into LMK in Clanfield and he replaced the MAF and timed the fuel pump.
It now went like a rocket!
The Turbo needs work as at sustained high speed the turbo shut down into safe mode.

Cosmetic
Threw on some 20's and lowered it 55mm!
Had to be done, no way was i driving an old work van without big wheels.
I also added clear side repeaters, badgeless grill and the headlight Mod.
I then replaced the beat up side door and changed my barn doors for a tailgate.

All this was done in 2010, the van was then used to haul stuff to the dump, loaded with plasterbord for a refurb and helped move my brother.
It then stood for a year in a garden while i had a MK1 Golf G60 project on the go.

I picked it up in June and replaced the battery.
It started on the button and sailed through its MOT!
The plan is to get it useable to sleep in and see where we go from there.

Pics to follow
 

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August 2010
Pics from the ebay ad









Lowered 55mm on 20's





Added Clear indicators and Badgless Grill





Rust in 2010



Rust in 2012

















I had been tempted to repair this myself, with great advice from other members, but have been helped out by a friend to give it a full respray at a good price.
Not going to give anything away just yet.
 

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Started on the interior.
First removed filthy seats and rubber mat.
I was left with this





looks worse than it is.
No rust or rot, the backing just left a bit of a mess.

Scrubbed the seats with a dishwasher and vanish mix, then pressure washed them and left them out for 2 hot days to dry.
They came up really well




 

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i then set about stripping the back.
i wanted to know the condition of the floor before i was fully booked in with paint




Got the boxes off and found they were screwed through the arch.



any ideas on how best to repair these?

I then removed the floor. This was also screwd down and small rust scabs had formed.
In general, it seemed good condition though.
I also started removing side panels





Spent a couple of hours scrubbing the floor and it came up really well.
The sides were mint




 

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Discussion Starter · #9 ·
Been a busy weekend.


Got the door cards off, headlining and all plastics trims off.
I put some flashing tape on the door skins which has made a nice difference




Did a little more insulation



And put the old wheels on for the paintshop


The van is now gone for 2 weeks.
Looking forward to the new colour but going to miss the fact it was just a van in a silly way.

Big thanks to Kel @ Audiosport for rapid delivery of the spoiler and off side rail smoothing panel and Tidy Transporters for the powdercoated rail

i also managed to convince the windscreen company to put in a windscreen with in-built aerial and tint across the top for no extra charge.

Cant wait to get it back
 

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nice work there mate, going through the same drill myself on my conversion at the mo, paintwork is nearly done, just fine tuning some bits and bobs as i decided two tone paint job, just for my reference how much are you paying for the new windscreen with tint and aerial ?? need a new screen as we broke ours taking it out before we removed all glass for the paint job :eek:
 

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Discussion Starter · #11 ·
nice work there mate, going through the same drill myself on my conversion at the mo, paintwork is nearly done, just fine tuning some bits and bobs as i decided two tone paint job, just for my reference how much are you paying for the new windscreen with tint and aerial ?? need a new screen as we broke ours taking it out before we removed all glass for the paint job :eek:
Just had a look at your thread - thats going to look great! T:

The cost of the screen is My excess, which is £80.
I will have to work out how to wire in the aerial - cant be that hard
The fitter is coming back to install once the paint is done.

Cant fault Autowindscreen to be fair

Matt
 

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Discussion Starter · #12 ·
Couple of updates from the weekend.

Thought i would paint the door cards and clean the wheels as they were off the van

Grubby, dirty cards




Cleaned rubbed down and plastic primered







Put other bits of cab trim in dishwasher while i cleaned the wheels



Came up a treat



polished and waxed wheels ready for the van to come back
Not perfect, they do have a few kerb marks from being on the van 2 years



 

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It's a nice colour either way.
Looks like theres good depth to the lacquer anyway. So should take a good wet flat and polish.
Well transform it when done:ILU:
Just need to get them wheels on it now!
 

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Looks like a great job and it's exactly what I'd like to do to mine. What paint would you recommend and for the prep did you sand back so that the plastic was flat with none of the original grain? Thanks for any advice you can offer.
 
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