Hello,
This is my first post as 71EJVan. Some of you will know me as GL1972 (Green German Look Super with 2110 and 17s). That car was originally bought to do up for my daughter's first car but I got carried away. Well I have decided to honor my commitment to her so I will be changing it by installing steel wheels and a standard 1600 twin port motor (she'll have the coolest car in school!). The motor is currently up for sale in the spare parts forum if anyone is interested in looking.
The project I have decided to do for myself will be a 1971 Bay Panel Van with a Subaru EJ20T conversion (another one to the dark and wet side!), rear disc brake conversion and 17 inch wheels. I purchased the van and brought it home yesterday and it is quite solid but needs some TLC.
The idea of a van is to get to the beach without having to tie my boards on the roof and also have some go to raise some eyebrows at the lights..... Surf and Swoosh!
The will be no metalic paint or plush interior going anywhere near this Van.
I will be posting updates and pictures from the Vans arrival to it's registration which I plan to be arround February next year.
I welcome your input (good or bad).
Regards
Brendan:jesusnn[ Edited on 30-8-2005 by 71EJVan ]
splittychick 路
Welcome Brendan,good to see another kombi owner on here.look forward to the updates.馃樀
h 路
welcome to the forum.. look fwd to your pics.. 馃檪
71EJVan 路
Finally got it home yesterday after a 215 klm round trip.
Its quite solid and straight however there is some rust to fix in the front floor, under the battery and the left A pillar.
Love the lowlight look. I must have been ok at tieing it on..never moved an inch.
What everyone's garage should look like!
Next picture should be of the EJ20T that will be grafted into it.
Till later.
Brendan:jesusnn[ Edited on 23-8-2005 by 71EJVan ]nn[ Edited on 23-8-2005 by 71EJVan ]
beerdoc 路
Well done Brendan
I also have 2 daughters in Ls and own a couple of splitty panels (not on road yet )
And to top it off my brother nearly bought your panel and would like to do suby convert
barls 路
good to see the new project brendan keep us posted
jvl054 路
Come to the Darkside our friend Brendan:vaderJVLRacing
Doug Sweetman 路
Now thats a good looking garage !!
Looks like a great project - I've often thought of selling my bug and getting a kombi - far more practical car, but I just dont know whether I'd be able to live with owning a car that cant be 'fanged' if you know what I mean......
Plus I change my mind every time I think about it.
It looks a great starting place, and will no doubt be another unique ride with your signature touch - quality 馃檪
Fossil 路
Nice Garage and VW's which make it
71EJVan 路
Fossil,
If it comes out half as good as yours I'll be rapt.
Dark Side here I come.
Brendan
71EJVan 路
Well I have a motor! EJ20T WRX with only 70,000Ks good compression on all 4 pots. Came with ECU, Loom and Intercooler. I may even hook up the AC at a later date. It arrives Saturday.
Bodywork starts this weekend with the removal of all non paintable bits (lights indicators etc). Probably will also pull the screen as well (needs new seal). I will also start the initial dolly work on the minor dents and if time permits cut the rusty sections out of the floor. Sounds like a lot but shouldn't be a problem if I get a few uninterupted hours at it.
Brendan.
71EJVan 路
Update:
Removed bumpers, grilles, lights, indicators. Pulled engine and fuel tank. Pulled back wiring (this will be shortened back to a junction point near the ECU and new loom for connection). Removed sound deadening in engine bay.
Brendan
Bringing the WRX motor home. Note the envious look on the bug parked behind the trailer!
The old and the new!
Fuel tank removed also, ready to start modifying to fit the EJ20T. (modifying sounds better than cutting).
VWCOOL 路
You gunna run a later/stronger,2-litre gearbox etc? What conversion plate u using?nn[ Edited on 29-8-2005 by VWCOOL ]
mattie 路
isnt that vwtyp2`s old van the loaf? if it is shes a very cool panel!
71EJVan 路
Going with this box at first. It's not a 091 but it surely is a lump of a gearbox. I'd say it has had some work in the not too distant past. You can see the edges of clean white gaskets at the nose cone. Haven't decided on the conversion plate yet. Will ring around today.
Yes I believe this was WVType2's van.
Brendan
Doug Sweetman 路
A little bit of mechanical sympathy goes a long way with gearboxes. I'm sure it'll do you happily for a good while.....
Until the boost bug bites and you want to drag the loaf..... 馃檪
pete wood 路
Man, I love that panel. Every time I saw it in the 4 sales I wanted it. 馃ゲ
Gonna be awesome with an EJ20t. Word to the wise though, if it's a 1600 box, it's gonna accelerate fast, but it won't last long. I reckon you'll constantly be be in the boost rev range. I think it'll be very toey to drive. I'd at least pick up a cheap 1800 box and some tall tyres or something. You might even think about converting to an Lbug box if you don't want a 091 just yet. That panel can't weight much more than a splitty, they put them in splitties heaps. Also, Jak and Boof are caning their Lbug boxes and can't break them.
Either way, lookin forward to what you do, might knock you over and steal it while you're not looking!! 馃榿
BTW, it'd look awesome with a narrowed beam 馃槈
71EJVan 路
Now you are scaring me... "I reckon you'll constantly be be in the boost rev range."
Anyone know the ratios of a '71 kombi box?
I want to go to the 228mm clutch but I'm not sure about performance clutches off the shelf that are still streetable (read: doesn't break your leg changing gears). Any ideas? The current box will take a 215mm and I could change the bellhousing and starter for a 2 litre one but what does that get me, a bigger clutch that I would need to get modified to handle the power? Would leaving it a standard size with a Kennedy clutch off the shelf be better?
I'm starting to ramble here!
I haven't ordered the adaptor and flywheel yet so there is still time to decide.
Brendan
pete wood 路
the 215mm is the 1800 clutch, I've had no problems with mine and, as I understand it, jak uses one as well and it's fine. If you do have problems then apparently the go is to use the standard friction plate but a heavier pressure plate. Kimm from indian does this and I know CBB are making the heavier pressure plates too.
If you want to go with a 2l box down the track then it probably makes sense to use the larger clutch, but as I said, if not, the 215mm will work just fine.
71EJVan 路
Pete,
The ring gear diameter on a 200mm clutch flywheel is the same as that on a 215mm clutch flywheel? Can I use both flywheels in the same 002 gearbox?
Anyone know?
If they are the same I may go with a 200mm flywheel and buy a Kennedy off the shelf clutch 1700 or 2100lbs.
I looked up a ratio calculator and with the 215/45/17 wheels I was going to install it would be super fast in the lower gears but rev too high for my liking at 110/120 kmh. Works out a lot better with 60 series tyres (don't know how available they are in 17 inch though). Would be worth changing the R&P at a latter date.
Brendan
kombi_kid 路
you should go a 091 box i reacon!!! just going on what i have heard through the conversion area! i would like the security of the 091 box compared to the 1600 box!! you can get good 091 box's for around $300-$500 anyways!
thats just my 2c worth plus i love the panel it looks awesome!
cheers
rhys
vw2b 路
091 Box ratios are much better for a bus. The 1800 box will be reving high at 100 kmph. The 091 will pull about 2900 at 100 .
kombi_kid wrote:you should go a 091 box i reacon!!! just going on what i have heard through the conversion area! i would like the security of the 091 box compared to the 1600 box!! you can get good 091 box's for around $300-$500 anyways!
thats just my 2c worth plus i love the panel it looks awesome!
cheers
rhys
you will pay $500 bucks for a crap 091, they are quite sought after now. But you might get lucky and get an ok one for that money. Alternatively you could buy a whole 2litre kombi cheap, keep the box and sell the rest to a wrecker or on the forum. Lot's of people want to convert to type 4 motors, so you'd probably cover your costs easy.
Not sure about ring gears, but I know the 1800 and 1600 002 boxes share the same belhousing while the 091 is a different behousing, so I guess the ring gear is the same. Ask your local VW mechanic or ring Volksbahn in Sydney, they know everything there is to know as far as factory specs go.
71EJVan 路
I might have a line on a 091 box. I'll find out tomorrow morning.
Buying another Kombi would mean definate divorce or at the least some serious expenditure at IKEA!
Brendan
71EJVan 路
Well I've got hold of a 091 gearbox. Exchange plus cash.
I probably will stay with the old 002 belhousing and starter so that I can use the 200mm off the shelf clutch. This will also mean that I could throw this engine in a dub if I desire without too much cost.
Made a list of all parts including steel and ally sheeting I will need to complete the job. Woah! lots of bits. I will post it here for criticism on the weekend.馃槀
Brendan
71EJVan 路
I'll try posting this long list. Still some things to add.
barls 路
just a few items
jvl054 路
71EJVan wrote:Well I've got hold of a 091 gearbox. Exchange plus cash.
I probably will stay with the old 002 belhousing and starter so that I can use the 200mm off the shelf clutch. This will also mean that I could throw this engine in a dub if I desire without too much cost.
Made a list of all parts including steel and ally sheeting I will need to complete the job. Woah! lots of bits. I will post it here for criticism on the weekend.馃槀
Brendan
You have done the right thing Brendan! more chance of getting divorce if you had to start or over again spending more money.JVLRacing
71EJVan 路
Quick Update:
Picked up the 091 gearbox a couple of days ago. On changing the bellhousing I inspected the crown wheel. No real discernable wear marks on the teeth and very little play. Looks in good condition. My 002 was in good condition also, would have made a great addition to an offroader with big wheels.
Picked up all the steel for the crossmember, fuel tank enclosure and radiator mounts. Took a list down to Metalcorp which included all the small cut lengths, came to $86 cut (who would use a hacksaw for those prices!!)
Also picked up a alloy core sealed unit radiator with twin thermatic fans for the right price.
All the metal is now cut out of the back of the Kombi to fit the engine (most of the engine seal apron and fuel tank shelf is now gone. Cleaned and painted the area ready for installation.
Engine is now cleaned ready for test fitting.
I will post some progress pictures on the weekend.
Brendan
Jeza 路
And once again I find myself staring at another of Brendans great projects. Man you're working fast!
If I don't get my car back on the road before you've finished this, I might just sacrifice it to the gods (...or something).
Looking forward to the photos
Cheers
Jeremy
71EJVan 路
Cleaned out the cargo area and found that the previous Signwritter owner was not too worried about spilling paint everywhere under the chipboard. She's had a hard life and has carried some serious weight over the years.
Picked up a near new alluminium core radiator complete with fans for $180.
Steel to make the new engine crossmember, radiator mounts and fuel tank, battery and ECU/wiring enclosure. I still have got to submit a drawing of the crossmember to my Engineer for approval before starting to build it.
71EJVan 路
Will be picking up new intake gaskets, exhaust gaskets, injector to manifold seals and rear main seal from Ryde Subaru this week. Easy guys to deal with. Want to make sure there is no air or oil leaks when I install this engine. Also as it is a MY95 engine the seals may have gone hard.
Have to also go back to engine supplier to pick up the Mass Air Flow Sensor that was missing. Jeremy from Tweakit was apologetic and rang back with 30 minutes to say that he had it there. Will pich up a air to water intercooler and circulating pump this week.
Regards
Brendan
71EJVan 路
A man and his grinder! This is me building the enclosure and mounts for the fuel tank and battery relocation and ECU and wiring. The unit will be alluminium lined and also have space for a surge tank, pumps and even a jack and wheelbrace. This will get a lot of weight forward and lower. Should assist in the handling.
nn[ Edited on 11-9-2005 by 71EJVan ]
pete wood 路
wow, you are a busy boy. :thumb
1303Steve 路
Hi Brendan
Looking good, are you going to put any sort of cross member on the bellhousing, if not you should consider one.
Steve
71EJVan 路
Steve,
I'm making a main crossmember that mounts between the chassis rails and picks up the Subaru engine mounts and will also make a brace between the shock mount towers above the belhousing and create a tranny strap. This will reduce twist and also provide support for the gearbox should I take the engine out. I need to test fit the engine and gearbox together to make sure it does not foul the intercooler though.
Brendan
Fossil 路
Looking good and you're not wasting time are you :thumb
71EJVan 路
I wish I could go faster! I get frustrated when jobs such as cutting out the heater tubes over the torsion housings take three times longer than expected. Finding rust that you didn't know about before. It's all part of life's rich texture I suppose.
Brendan
kroozzn63 路
yeah its "loafy" unfortunatley i had to pass her on to a better life and its looking good
71EJVan 路
Well after a week and a half where I didn't touch it, I finally got approval from my engineer for the crossmember design and the adaptor kit turned up. The main framework for the tank enclosure is mostly made. Cut out for the engine hatch (big access!). Fitted the adaptor plate after a small amount of trimming and mated the gearbox. Fitted the old front mount to the 091 box and trimmed the studs as they fouled the torsion housing. Sat the engine/box in place and bolted up the front mount. Chocked the back for level and centre (checked this many times).
On the weekend I made a big timber adjustable crossmember. Set it in place and set angles whilst checking for clearance. Transfered these angles and all my other measurements to the concrete floor. The next job was to cut all the steel to match the angles drawn and started welding. After a couple of test fits the crossmember is almost complete.
Here is some pictures of the progress.
Brendan
Motor and box in place with front mount bolted up. Plenty of room in there without the tank.
Another view showing intercooler clearance and space around engine.
Fuel tank framework almost complete. Just need to weld in tank and battery supports.
Dummy timber adjustable crossmember used to work out angles.
Dasdubber 路
Great stuff Brendan - keep up the great work!
71EJVan 路
Hey Alan how's the surf and crowded lineup on the Goldy? Nothing down here last weekend hence the work on the van.
Brendan
squizy 路
Mate I've got to find me some minutes to come down and have a look. You going to the Mariners on Friday? Will call you tomorrow.
Fossil 路
That's some great work your doing
E 路
Very cool Bredan. And I don't know If I thanked you for the mags, they were alot better than my sexy hubcaps.
71EJVan 路
Thanls guys.
I will have the crossmember, radiator mount and fuel tank mount finished this weekend. That should allow me to start hooking things up. Need to source some stainless and ally tube for the cooling systems.
Brendan
h 路
wow its been a while since i saw this post..
great job so far..
bet you cant wait to take it for a spin..
71EJVan 路
Yep, I can't wait to throw the boards in the back and take it for a spin!
71EJVan 路
Took an extra day off for the long weekend intending to put some serious hours in on the van. Furtunately (or unfortunately) got some surfing in but didn't get everything finished.
The crossmember is now complete and the radiator mount is halfway there.
Here is the completed crossmember. It picks up the existing WRX engine mounts and also has a frame to connect to the 4 bottom belhousing to gearbox bolts via 2 rubber mounts. The tabs on the sides and the 25x25mm sections will bolt up to the original crossmember hangers at the back of the engine bay. This will assist in reducing any twist at the bottom of the frame under acceleration. You can also see in the picture the transfered measurements on the floor.
Brendan
[ Edited on 4-10-2005 by 71EJVan ]
[ Edited on 4-10-2005 by 71EJVan ]
Doug Sweetman 路
Tidy work ! getting closer every flat weekend eh ?
richbaker78 路
hi- very impressed with your progress -especially as im doing exactly the same the other side of the pond! Ive a 70 bay with 091 box, EJ20T engine, 17 inch porsche boxster alloys and porsche disc brakes all round. Your slightly more advanced than I am on the engine fornt but that should al change soon (ive got a week of in November)
Interesting to see that your planning to mount the tank inside. My plan is to fit the fuel tank shelf higher up and loose some fuel capacity this means i can retain a cut down firewall and not waste space. If you want to find out more about my conversion mail me richbaker78@hotmail.com im watching yours with interst - keep up the good work!!
71EJVan 路
Rich,
I'm not worried about losing the space. I'm making a new enclosure in front of the existing engine/fuel tank one. This ventilated enclosure will house the tank, fuel pumps, surge tank, air conditioner, battery and all electronics. It will also have compartments for tools/spares etc. No space will be wasted. Basically the top will be 1.9m long from the back so I can carry my surfboards on and also make a bunk if need be. There is still plenty of room to mount a microbus middle seat in the factory spot as I intend to do. The space where the fuel tank was will have the air/water Liberty intercooler, have enough space for the downpipe from the turbo to loop around the LH drive shaft and also mount one of the intercooler raidiators (with ducting) on the RH side.
Regards
Brendan
71EJVan 路
Been a while since an update.
Here is a pic of the completed fuel tank, battery, electrics, fuel pumps, storage housing. The tank will sit in timber mounts on the two rails in the centre and be held down by steel straps (I'm re-useing the old ones). The fuel tank area will be sheeted in 0.4mm steel and be sealed with both up and down ventilation to the outside (40mm pipe). the rest will be sheeted in ply and be trimmed in waterproof carpet. There will be 4 accessable enclosures. 2 for wiring and electronics, 1 for battery (you can see the frame on the lower right hand side) and 1 for tool storage (might put a second battery in here).
Regards
Brendan
71EJVan 路
The wiring harness in pretty much complete and in.
I'm going to re-use the fuse blocks and relays from the original car. Going to feed the front of the van from this. I have identified all of the AC wiring and left it in the loom as I will AC the van at a latter date. All I have to do is take a feed to the front to pick up the original fuse box, have the ignition switch control a relay at the back for the starter (40Amp) and rerun the rear lights.
The looms took 4 nights and one day to identify, rehash, shorten, remove unused, and recover.
Regards
Brendan
71EJVan 路
After much measuring cutting welding and grinding the radiator mount is complete. Here is three pics of the completed mount. The last one is a test fit under the van chassis. I will make some modifications the rear of frame to raise it a little. The scoop will be sheeted in 0.4mm and there will sheeting in front of the scoop under the floor to smooth the airflow out a little.
Regards
Brendan
richbaker78 路
top work that - what rad is it? is it the std subaru one?
Keep it up - Rich
seagull 路
Looks good ? please the motor suport frame is 50 x 25 x 2.5 mm wall ?
seagull
71EJVan 路
The radiator looks like a Subi but alas it is not. Don't tell anyone it is a Deawoo Leganza.
Seagull the moto support is 50x25x3mm