im just reposting this thread as it was lost with the old forum.
im a long time getting round to starting this project but well keen to get stuck in!! i bought it off ebay well over a year ago, it had just came in from malta, body removed, running a toyota td engine. ive got a rotten mk5 donor van from which i intend to use engine, box and running gear including the ifs subframe/power steering rack etc.
heres a few pics from when i brought it home last year on marks recovery.
i had it tucked away in the uncles barn till i pulled it out the other day to get stuck in!!
ive just made a start on the stripdown, no major nasties so far, usual repairs needed in spots but no serious corrosion found as yet, hard to beat the maltese climate!!
front end off.
loom and brakes stripped out, lump and box next!!
more progress soon hopefully!!![/quote]
Last Edit: Feb 3, 2013 2:58:53 GMT 1 by oldskooler
i continued with removing the bits that wont be going back!
nasty crack behind the steering box plate indicating that the old girl worked hard in her lifetime!!
no nasty horrors under the plate this side.
next i got the donor in for stripping, oo mk5 just turned 100,000 miles, driving mint but rotten as a pear!!! the late mk5,s really did go badly. i picked this up with a new battery and recent full exhaust for 200 quid.
just for the heck of it while i had the lump and box on the crane i sized it up in the mk1, looks snug enough!
ive had this subframe with twin wheel struts sitting for a while now in planning for an ifs conversion. so the plan was to use this one as the jig.
first i took out the springs and welded a bar in each side to hold the two wishbones in the same ride height position.
i then bolted the subframe into the mk5 shell, got the two front hubs facing dead straight before welding a piece each side of the shock mountings to the spring housings.
so thats the castor and camber locked in position. the flat mounting face of the subframe sits level in the mk5 so in theory if i get it sitting level in the mk1 also my castor and camber should be pretty close to spot on,....well thats the plan anyway!!
next i chopped out the top mount turrets from the mk5. i got a loan of a plasma cutter form a guy at work which shuld be a huge help, it certainly made short work of the turrets!!
i retired the mk5 for the moment till i need to rob some more bits from it as i go along!!
so in with mk1 again and beam axle out.
i was well delighted with the condition of the legs after a cleaning where the subframe ill be going.
with a bit of fettling on the lift i leveled the chassis best i could so i could use it as a reference for the subframe.
so after a bit of jostling with jacks and measuring i got the subframe in hopefully the right position. now heres something i wasnt expecting,......when i tried the mk1/mk2 wheel on the mk4/mk5 hub it wouldnt fit. pcd of studs a wee bit wider on ifs hub. will deal with this problem later but just wondered.
as this is a twin wheel and they generally sit a bit higher im hoping to get away without notching the chassis legs as is done with single wheel vans. im figuring the inch or so wont make much difference and will leave a bit more clearance for the engine and box. ive called in the help of a mate who is a whizz at fabrication and welding to give me a hand with this part of the conversion. the second pair of hands makes a huge difference for getting bits into place etc.
this wedge shaped wee level the old man had lying about came in very handy for setting the subframe level to correspond with the overall chassis. i plan to use two wedge shaped mounting sections with captive nuts welded inside to box the chassis down to meet the subframe. should be a good strong job especially as ill not be touching the chassis bar drilling a a pair of holes in the bottom for the front captive nuts to clear.
i got some 60mm x 60 box section with a 3mm wall which shuld do the job.
this as far as we ave got for the moment, one drop bracket cut out and trimmed to fit. there will be lots more measuring and head scratching before the first weld im sure!!
got the two filler sections shaped and tacked up in place.
then took down the subframe and welded up fully.
for the front fixings i had first thought about just using the existing spring hangers but even though the r/h one is in very good order..................
the l/h one has been plated over on each side with a bit of rot lurking underneath.
so the decision was made to go back to the bare legs and make up a set of tidyier looking drop brackets for the subframe.
and surely when i started peeling the repair plates off i found some more nasties beginning to spread into the chassis on the left side. so we ill be cutting the last couple of inches out and making a piece to go in. this is slowing progress a little but i think its worth it as the rest of the chassis is so mint.
hope to get another few hours at it tomorrow.[/quote]
got the wings off with a bit of work, these vans really were well put together with the wings bolted internally aswell. i took them off as carefully as i could leaving the option of using them again if i cant find replacements.
the top chasis repair sections are now in as well.
underwing areas are not too bad, just a small repair section needed each side, having the wings off also gave good access to the top mount turrets to weld them up on the outside.
i nicked a few more bits from the mk5 for some mocking up.
i also fitted a mk2 pedal setup which is a lot simpler than the mk1 pedal assembly. the bulkhead had cracked around the large hole used for the mk1 setup and needed replacing anyway.
also set about modding the mk5 servo/cyl to fit.
re drilled the bracket to take the two bolt fixing.
i had to space it out a little as the brake was on slightly when it was bolted up to the bulkhead. so i just made up a shim from a bit of 2mm aluminum sheet.
the mk5 rod was a little short so i made up a sleeve and mated it to the mk1 end which has adjustment which ill be handy.
and sitting in place, worked out easier than i thought!
next plan is to take it for blasting before tackling the rest of the body repairs. ive got it rolling again on a pair of 6 stud mk5 rims i got the loan of.
well with the recent spell of dry cold weather i managed to get her away for blasting and back dry thankfully.
it revealed a few patches and repairs i hadnt seen and a few more small repairs that are needed, but overall im well happy. the chassis and outriggers under the cab are mint. 8)
ill be bringing it back for a light blasting after we have done the rest of the repairs and ill get the back half of the chassis done then as it needs little or no work. then it ill be etch primed straight away hopefully.
there will be a slight delay in progress for a while as we now have marks recovery on the lift for some cab floor and chassis attention for the mot. it makes the garage look pretty small when its on the lift!!
we got a bit more time at this project recently. i had been keen to get the di and box mounted to make sure there were no clearance problems with the ifs etc. i also wanted to use the mk5 mounts as it would be easier to clear the subframe with them.
rather than using the mk5 floor section i hope to get away with just moving the hole for the mt75 thus keeping the original floor mat.
i used a bit of box section across between the legs and under the crank pulley to keep things roughly in place to size it all up.
we got it as far back and as high as possible before hinging the ifs subframe back up into place to see if there was enough clearance.
and all looks good, just enough, i reckon just to grind a couple of fins off the top of the bellhousing for comfort, its that close!!
clearance up front looks ok too.
next to the engine mounts.
although its not touching maybe a small shave off this area to allow for movement.
bottom of bellhousing close to rack but still enough to play with!!
for the gearbox crossmember we decided to cut back the spring hanger mounts and weld on a couple of plates with captive nuts to attach it to.
and all done (nearly) still have to box it up around the mount in the middle.
we have since got the engine and box out again to weld up the mounts fully to the chassis rails etc. im well happy to have this much sussed out. still plenty of work to be done but gettin there slowly![/quote]
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