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Discussion Starter #21
It's a Friday night, and have spent the last 4hrs trying to buy a few random items. It's a frustrating experience because most VW online parts suppliers won't sell to Australia, or the postage cost is outrageous and unjustifiable...it's ragetastic, gah! It really shouldn't be this difficult, here's just one example of many doozies ...

 

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Discussion Starter #22
Way back when I first got the van, I started to insulate and did a really terrible and half-assed job. It was a complete failure, so have decided to strip it all out and do it properly. I've got proper sound deadening pads arriving in the morning, and today the acoustic/thermal foam (also a moisture barrier) arrived.

Having learned from my previous mistakes, I didn't bother "cheaping-out" this time, and went straight for the professional stuff supplied by a local specialist. The results are undoubtedly going to be worth the time, money and effort. I also picked up a couple of cans of adhesive (just in case!), and two application rollers which will speed things up with my Dad helping out. :)









I haven't decided on which carpet colour/shade to line the van with, but figure I've got enough work to do before I'm ready for that stage!
 

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Discussion Starter #23
During the down-time, I've also been working out some solutions for bed/couch and kitchen. This has been really frustrating, as every company but one has either ignored me, or flat-out said they're not interested in sending anything to Australia. I really struggle to understand this stupidity, esp when it'd be me paying for the postage. We're very limited for choice with parts and accessories, so literally have no other choice than to buy from Europe and is a catch-22. This lazy and unhelpful attitude to doing business really grinds my gears! :(

Left with no other choice, I found the perfect design for a bed/couch, and am in the early stages of reverse engineering the drawings so that I can build it myself. Having only basic dimensions, I'm just working my way backwards...and fine-tuning the dims as I go. Creating this will be the next major project to tackle after lining the van. :)

 

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Discussion Starter #24
I've had a few parcels arrive this morning, and was chuffed to find my new LED driving lights and wiring harness, plus a light mount bar. I got these for an irresistible price courtesy of the current Fathers Day promotions atm. They'll look great on the van, complementing the build-direction, and I'm certain they'll come in handy at some point.













The other delivery to arrive was my sound deadening mats and it excites me to no end being able to start with the van interior. There are 48 sheets of it, each measuring 500x300mm, so the van should be pretty darn quiet by the time I've finished, haha!

I'll give a huge thumbs-up to CarBuilders for the excellent customer service and insanely fast postage for all of the interior lining goodies! :)



 

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Discussion Starter #25
I've got most of the rear interior sound deadened today! It was a bit of fun removing a lot of the clips because they are so old, but eventually got there. Then there was a heap of vacuuming and wiping down, then applying wax and grease remover over the surfaces.

The sound deadening pads were fantastic to work with, easy to cut and mould, and their impact was immediate. I probably didn't need to apply quite so much, but the noise levels in the van are noticeably quieter, and the tinny-sound knocking on the panels has completely gone. I'm genuinely shocked at how effective they are!

I'm probably going to need one more box to do the front cabin, so that short-order was my bad. Tomorrow, I've got to tackle the roof, tailgate and wheel-arches (ran out of daylight to finish today). After that, it's time to unleash stage 2, the rolls of accoustic/insulation foam! :)







 

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Discussion Starter #26
A very productive day, I finished off all of the sound-proofing for the rear of the van! In total, I used 48 sheets of 500x300mm, and it was literally "just" enough to finish the job...there wasn't a single scrap piece left after covering all surfaces. Whew!

I had to go for a quick drive to fetch a click-n-collect purchase, so it was a great opportunity to test the sound levels while driving. I'm genuinely stunned at how quiet it is at the back...eerily silent, and it highlights just how noisy the cabin is. As soon as the rear is finished off, I'm getting straight into deadening and insulating the cabin.

I also made a start putting the accoustic/thermal liner on one panel just to see what I'm up against tomorrow. It's a lot harder than it looks, because you only get one go and it's stuck down properly. I'm 90% happy with that panel, and will no doubt improve the further into the job I go. For this reason I'm leaving the roof sections til last haha!







 

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Discussion Starter #27
Well that's the end of sound-proofing and insulating the rear of the van! I've got a splitting headache, sore knees and fingers, but am patting myself on the back for smashing this out for 3 days straight. The black accoustic/thermal liner was really tricky to work with as I mentioned before, so had to slow myself down for a better result. Wheel arches were a right pain, and somewhat mangled the first one, but the second one came out much better by massaging it on with my thumbs in multiple directions.

I'm going to sit down this evening and decide what colour carpet to line the back with, and put the order through. I'm lucky enough that my van came with full wall panels, so this will definitely make things easier! :)









 

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Discussion Starter #29
I had a few hours spare this afternoon, so decided to get the spotlights installed. The first thing I noticed when removing the front bumper was that both 13mm bolts either side of the number plate were missing! This was the first time I'd removed the bumper, so to discover that the whole thing had been hanging on by 4 small bolts by the wheel arches...yeah, wow!

In order to give the lights some strength while mounted, I first cut up a bracket to pop behind the bumper. I also had to find some nice strong bolts, and digging around in my bucket of randoms, found some torx high-strength ones. Once mounting the front bracket with the lights on, everything was rock solid on the bumper.







Once the bumper was reinstalled, it was time to run the wiring harness in the engine bay began. It was a pretty straightforward job and found a few nice ways to route and secure the cables. Finding somewhere to put the relay was tricky at first, but found a perfect spot eventually.







I didn't fancy pulling apart the dashboard to pull the wire through to the switch area, so took my time and eventually fed it through. Here's where I realised a slight oversight...the switch is smaller than the gap provided for the factory switches, so I'm going to have to find and order something that fits nicely.



And here's the finished product! I tried them in the dark earlier, and can confirm that they are insanely bright. I'm really glad to have got this job done, and looking forward to the next job of carpeting for the rear of the van...fingers crossed it arrives tomorrow! :)





 

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Discussion Starter #30
Not much happened today regarding the van as I was waiting on things to arrive, but the heated seat elements arrived by courier which was perfect timing tbh. The Golf seats are arriving at some stage tomorrow, and that was a real hassle trying to organise a courier to collect them, as we're in a strict 5klm travel restriction due to lockdown. $170 for the privilege of having them delivered (!!!)...it's super annoying but honestly didn't have any other choice given the circumstances, it's just the crazy way things are atm. The carpet for the rear of the van is coming in the morning, so it's going to be a busy next few days for me! :D



 

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Discussion Starter #31
Well my carpet arrived today! I ended up going with the dark grey because it hides marks well (it is a van afterall), and the carpet is really high quality, so am expecting it to be a bit easier to work with than the cheaper stuff out there.

The Golf Gen6 seats also arrived after a big delay thanks to the courier company being slack. The seats are in flawless condition, very comfortable to sit on, and match the interior perfectly, so they're going to be a massive upgrade compared to the old ones. Now I'm up to the fun part of installing the heated seat pads! I'm still figuring out how to remove the fabric on them, so might have to search around on the net for some instructions, because it's not particularly obvious. I suspect it's going to be a pain in the backside haha!



 

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Discussion Starter #32 (Edited)
Well, the best intentioned plans don't always go as hoped, and the heated seat pads were a fail...the seat cushions have deep channels with plastic bars and clips and there are also a heap of Bastos clips in the backrest, so there's no real way of installing them without having the fabric loose in the centre sections. Oh well, it was worth a try!





Onto the seat installation. These aren't a straight bolt-on (which I was half expecting), and will need some plates made up. My Dad's neighbour is an engineer/fabricator, so he took a look at it, did some measurements, and we'll get started on it tomorrow evening. I suspect this will involve a couple of evenings to get both seats done properly, which is fine by me.

I've worked out my cutting plan for the carpet, to maximise the material and have it all running in the same direction, and will get cracking on that project in the morning. :)
 

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Discussion Starter #33
After a slow start, I got some mojo and managed to get most of the interior panels carpeted. I took my time, applied wax and degreaser on the surfaces, applied the adhesive correctly (with waiting time for tackiness), did all the fiddly cuts, and used the roller over everything to promote good adhesion. It was time consuming, but totally worth it...as they say, do it once do it right!

I ran out of spray adhesive which was a bummer (used 2 cans so far), but I knew I didn't have enough and purchased some more the other day. It was on backorder for a couple of days, but hopefully it should arrive tomorrow so that I can continue. The carpet looks and feels so plush and premium, and was super easy to work with. :)









 

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Discussion Starter #34 (Edited)
Yesterday was productive, but not as much as I was hoping for. The adhesive still hasn't turned up (the postal services fault), so was unable to continue with carpeting. I'm at a complete standstill with that until it arrives which is rather annoying.

I did have a delivery of some new headlight bulbs however. It's been on my wishlist and never got around to it. After seeing the difference the spotlights made and how yellow the headlights looked, I simply had to do this.



With little else to do, I decided to finally remove the cargo barrier. I had always expected this to be a pain, but with a lot of WD-40 and persistance, I finally managed to wrangle it free. It's amazing how completely different the van feels now, so open and free! It will also make things a lot easier with regards to the seat installations, as well as soundproofing and insulating the front cab.



The weather is awful today, so there's not much more I can do to the van atm. I've dropped off the seats and base to have brackets made up and will have them back in a few days time. :)
 

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Discussion Starter #35
The adhesive spray and the extra sound deadening arrived this afternoon, so I managed to get a bit done in the van regarding the lining. I'm so glad that I can push on again. Stupid me misplaced my phone in the morning and only just found it before dinner, but I'll be sure to take some pics tomorrow of the progress. It's looking amazing so far! :)

I also removed the flooring and gave the floor-pan a good sweep and wipe-down. Everything is like brand new under there, and unlike your poor souls in the UK, there is no rust to deal with. Woohoo!

In other news, and yes I feel compelled to brag, but I have scored "unobtainium". Yep, a brand new, genuine cruise control!! I had been looking online for weeks without any success, and thought it a long-shot but called the local dealership anyway. It turns out there were 2 left in Australia, so I snapped it up immediately. I assumed it was a kit, as nothing was mentioned about the wiring harness for it, so atm I just have the stalk and will have to call up tomorrow about the harness. Slightly annoying but meh!

 

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You'll certainly enjoy your cruise control when you've fitted it, relatively easy job.
How are your spots when the van is in motion? Do you get any wobble?
I have the same bracket but at the moment mounted mine on the grill with wine bottle corks cut to size between the lamps and grill to stop the vibration, I'll fit the bracket at some point in the future....along with all the other jobs!
 

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Discussion Starter #37
Hey Pickledog! So long as you mount the light bracket with a support behind the bumper to strengthen it like I did, it's absolutely solid. There's 2x 13mm bolts immediately either side holding the bumper onto the rail, so that also helps to keep things tight. Also having the thin strip of rubber between the bracket and the lights helps dampen vibrations. :)
 

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Discussion Starter #38
Another day down, more work done to the van, even though I struggled a bit today because I hurt my neck, so had to take it easy. Here's the updated pics of the carpeting...please ignore the fact the clips are light grey as I'm still waiting for black ones to arrive! There's still a ways to go til it's finished but it's really coming together nicely...not rushing, just taking my time and doing everything perfectly. :)















I painted the aluminium strip black



This last one is just put in place and not secured down yet.
 

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Discussion Starter #39
Oh I almost forgot...my mate sent me a pic that my tyres have arrived for fitting on Friday morning! Michelin LTX Force's in 215/75R15's. They look amazing already! :)

 

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Discussion Starter #40 (Edited)
Timing could not be better for this to have arrived this morning, with the tyre fitting and alignment tomorrow...40mm billet spacers for the rear springs! To make the order more cost-effective, I also ordered a clutch pedal bracket to prevent the failure I've seen others have. A massive thank you to Creations Motorsport in Birmingham for fast postage, but also for being one of the only UK companies so far that were happy to send to Australia! Why others make it so impossible is beyond me tbh...



 
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