Fitting Carat (big) Bumpers & Planking

[Titus A Duxass]

Edited to include new information.

Just a quick guide for anyone, like me, who is thinking about fitting OEM big bumpers and planks.
I got a lot of this from some German sites/forums and therefore this is for a LHD Van.

Front Bumper


Required Parts :
1 Bumper 255 807 111 C (1 off)
2 Bracket 255 807 115 (2 off)
3 Spring Washer N 021 241 11 (6 off)
4 Washer M8x12 N 044 147 3 (4 off)
5 Bolt M8x18 N 901 680 01 (2 off)
6 U-Plate 255 807 142 (2 off)
7 Rubber Pad 281 807 318 (2 off)
8 Bolt M8x22 N 010 241 18 (2 off)
- Holder (see photo below)- 255 804 641 (2 off) These two items may not be needed if your bumper has two vertical ribs six inches in from the ends. - to be confirmed.


Mounting:
The Bumper will be attached to the original mounting points with the M8x10 bolts & washers.
The holder (2) must be fixed (welded) to the body to that the M8x22 & washers on the end of the side brackets can fitted.

Rear Bumper


Required Parts :
2 Bumper 255 807 311 L (1 off)
3 Rubber Pad 281 807 318 (2 off) This part number changed to 701 807 318, that part number is now obsolete. It looks like it is a small rubber pad. 701 807 318 is now available from VW Classic Parts - 1,33€
4 Bolt M8x12 N 010 237 6 (6 off)
5 Spring Washer N 012 241 11 (6 off)
6 Bolt M8x22 N 010 241 18 (2 off)
7 U-Plate N 900 333 01 (8 off) A U-Plate turns out to be a Washer (M8 20mm OD)
8 Bumper Right 255 807 324 A (1 off)
8 Bumper Left 255 807 323 A (1 off)
9 Bolt M8x25 N 010 242 22 (6 off)
10 Bracket 255 807 347 (2 off)
11 Bracket 255 807 381 (2 off)
12 Bolt M8x16 N 010 293 5 (4 off)
13 U-Plate N 011 670 16 (2 off) A U-Plate turns out to be a Washer (M8 32mm OD)
14 Bracket 255 807 393 (2 off) - Available from VW Classic Parts (Ca. 6,00 Euro)
15 Spring Nut N 015 432 2 (4 off)
16 Screw 6,3x13 N 013 976 1 (4 off)
17 Bolt M8x18 N 010 239 11 (2 off)
18 U-PlateN 904 772 01 (2 off) A U-Plate turns out to be a Washer (M8 24mm OD)

Mounting:

Remove the either the bumper holders (1) or the Tow Hitch
Now fit the holders to the bumper centre section (2).
Then refit bumper holders with bumper.
The bumper side pieces and brackets are straightforward.

Planking


Required Parts:
1 LH Door Plank 255 853 953 A (1 off)
1 RH Door Plank 255 853 954 A (1 off)
2 Planking Screw. M6x25 N 010 512 1 (17 off)
3 Spring Washer N 012 006 4 (17 off)
4 U-Plate N 011 523 18 (38 off)
5 Rivet 4,8x14 N 016 201 1 (38 off)
6 Locking Plate N 900 602 01 (17 off)
7 Plate 255 853 999 (17 off)
8 Nut M6 N 011 006 24 (17 off)
9 Sliding Door Plank 255 853 964 B (1 off)
10 Forward RH Plank 255 853 974 A (1 off)
11 Forward LH Plank 255 853 983 A (1 off)
12 Rear RH Plank 255 853 984 A (1 off)
13 Holder 255 853 985 (11 off)
14 Holder Sliding Door 255 853 986 (4 off)
15 Holder Doors 255 853 993 (4 off)

Drill Ø 5mm holes as shown on the diagrams below.
Required Parts:
1 LH Door Plank 255 853 953 A (1 off)
1 RH Door Plank 255 853 954 A (1 off)
2 Planking Screw. M6x25 N 010 512 1 (17 off)
3 Spring Washer N 012 006 4 (17 off)
4 U-Plate N 011 523 18 (38 off)
5 Rivet 4,8x14 N 016 201 1 (38 off)
6 Locking Plate N 900 602 01 (17 off)
7 Plate 255 853 999 (17 off)
8 Nut M6 N 011 006 24 (17 off)
9 Sliding Door Plank 255 853 964 B (1 off)
10 Forward RH Plank 255 853 974 A (1 off)
11 Forward LH Plank 255 853 983 A (1 off)
12 Rear RH Plank 255 853 984 A (1 off)
13 Holder 255 853 985 (11 off)
14 Holder Sliding Door 255 853 986 (4 off)
15 Holder Doors 255 853 993 (4 off)

Drill Ø 5mm holes as shown on the diagrams below.

Door Bracket Holes.


a = 70 mm
b = 25 mm
c = 35 mm
d = 80 mm
e = 226 mm

RH Side Bracket Holes.

a = 30 mm
b = 15 mm
c = 53 mm
d = 365 mm
e = 60 mm
f = 33 mm
g = 65 mm
h = 180 mm

LH Side Brackets



a = 30 mm
i = 10 mm
k = 390 mm

Clean (T-cut, etc.) body work.
Apply masking tape (helps to stop the drill sliding off the mark), mark up.
Seal edges of holes with paint.
Apply a small amount of seam sealer on holder mounting face where it meets with the body work.

Planking locking screws – These rust like buggery, either buy stainless ones (Brickwerks – 23,44 ukp) or use lots of coppaslip.

I hope this is helpful.
Please send me corrections as required.

Edited to include new information.

[..lee..]

they look good but i put a set on my 2wd and i`d never do it again flimsy and vulnerable and mine are genuine vw to.

[Titus A Duxass]

To go from this


To this


First of all you need these

Big Bumper Mounts - Cheers Snozzy


Some more brackets


Some nuts, bolts, washers, screws and rubber pads.


Fit the mounts to the centre section of the bumper


Fit the end pieces to the centre section (I gave everything a quick squirt of paint to slow down the rust).


Remove the original bumper mounts from the bus and slide the complete bumper assembly into place and bolt up mounts.

The end pieces are secured with the remaining brackets, two bolts, two sheet nuts and two large self-tappers
It's a bit fiddly but does come together.


The holes for the sheet nuts are already in the body


Simples.

[Titus A Duxass]

- Holder (see photo below)- 255 804 641 (2 off) These two items may not be needed if your bumper has two vertical ribs six inches in from the ends. - to be confirmed.


These are not needed if your bumper has 7 vertical ribs inside, this ribs sit on top of the crush section and support the bumper.

You do need the large side bracket and you may have to drill a hole in the chassis/body and use a long bolt to secure them .

[Titus A Duxass]

I actually got a round tuit so was able to fit the planks.

From this.


To this



A roll of 30mm masking tape helped with the positioning of the holes.

Once the top holes were drilled and then painted the holders were fitted.

Close up showing one of the large holders mounted.


I found it easier to pop-rivet the holder on with by the upper hole and then centre popping through the holder to get the correct location for the lower hole.
Fit the planks before you drill the lower holes so that the holders can be positioned correctly, then mark the position of the lower end of the holders on the bodywork/door.

Now I have to decide; do they stay satan black or do the get colour matched with the new paint scheme (VW Toffee Brown met.)?

[Big Boris]

those planks look the nuts ,and the wheels too ,did you get them powder coated ?(the wheels)
do you know if any of thease parts are available to buy ,or is it a case of serching shows for second hand ?,i have some of the plank set but i am missing one piece also not sure if i have all the brackets

[Titus A Duxass]

those planks look the nuts ,and the wheels too ,did you get them powder coated ?(the wheels)
do you know if any of thease parts are available to buy ,or is it a case of serching shows for second hand ?,i have some of the plank set but i am missing one piece also not sure if i have all the brackets

The wheels are finished with rattle cans.

I don't think any of the planking parts are still available, you have to get them of ebay.
There's a good amount on German ebay at the moment.

I have a load of spare brackets/holders.

[Bluerinse]

I have a load of spare brackets/holders.

Hi Titus,
Firstly I must say that your post is really helpful. I have a 1982 T25 van conversion that I am fitting big bumpers.
After seeing your post I am missing a few parts;

From your first post I am missing
Front bumpers
Holders - 255 804 641 (2 off)
Rear bumpers missing the following;
11 Bracket 255 807 381 (2 off)
12 Bolt M8x16 N 010 293 5 (4 off)
13 U-Plate N 011 670 16 (2 off)
14 Bracket 255 807 393 (2 off)
15 Spring Nut N 015 432 2 (4 off)
16 Screw 6,3x13 N 013 976 1 (4 off)

Please PM me if you have the following available and I’ll buy them from you.

Regards
Andy

[silverbullet]

Thread revival! All very useful, I have to re-work the "Wagenworks" copy kit that is on my rhd bus, the plank brackets are rubbish and the rear bumper is marginally secured, but the while kit is very light

[Titus A Duxass]

I've found out where these supports go.



While browsing through this thread on a the Bulliforum.com - http://www.bulliforum.com/viewtopic.php?f=30&t=66344

I found this picture
http://imageshack.us/photo/my-images/502/dsc02393l.jpg/" onclick="window.open(this.href);return false;


They are welded to the crush member and they support the big bumper from inside.
If you have the big bumper that has ribs inside of it you do not need these.

[Bluerinse]

Hi Titus,
Just thought after all this time I'd share photos and thank you (albeit a bit delayed) for your good advice in installing my bumpers.

Cheers mate.

IMG_3214.JPG

IMG_3215.JPG

IMG_3216.JPG

[Bluerinse]

And 3 more.

IMG_3217.JPG

IMG_3218.JPG

IMG_3219.JPG

[Bluerinse]

By the way my bumpers are not OEM, but copies bought from Blaze on ebay.
http://www.ebay.co.uk/itm/VW-T25-T3-Big ... 2579402bca

[Hammerbus]

Hi there,

although this topic is 'old', I have a question re. the rear bumper mounts. My T3 is a Canada Vanagon, and I want to fit a standard european bumper, like the previous owner did on the front as well. Can I just simply remove the top part of the bumper mounts (the part that is extra welded on what seems like the original mount) ?
I post a pic of the supports as they are now.
(old bumper is broken and was epoxied to the supports....)
Thanks for any info! K/R, Hammerbus.

[Titus A Duxass]

Don't destroy the big bumper brackets, they are sought after.
Pick up a pair of normal bumper brackets, I'm fairly sure somebody on here will have a pair.