1.6td to Volvo b230a...

[carpmaster]

Looking good ! Dosnt seem to be too much sticking out the back - you should be able to get it looking quite tidy I think.
Inside the raised level floor may not be too much of a problem , Devon conversions have a storage box about 4 or 5" heigh under the rear cushion and still use a rock n roll bed, Autohomes have storage under the rear cushion as well although they use a slightly different bed mechanism.

Cheers Richard..given me something to research there. I have been thinking about what i could do with the back..its opened an opportunity to form a rear access between the rear lights. i want to be able to access the service belts and water pump..just incase. i am thinking of keeping the cut out section on the top..tidy it up and reinforce/stich it internally...if i do this i can undo the cambelt cover..first things first..finish what i'm doing..
Tom

[New Kentish Campers]

From reading all through the thread, then I think you've done well with this, despite some of the negatives thrown at you. A perfect world, it aint!

Good luck with it

Doug.

[carpmaster]

Glad to see it's coming together Tom, hope that final installation all goes ok and you can get it mot'd and moved in time for the end of space rental
ps you can mod the petrol rubber mount to your hearts content it's not required back here as I have a new one for the pickup when that finally gets an engine and gearbox

Thanks Aidan..i was going to ask if okay to mod the mount..going to give myself the option of trying both..good luck with your pick up..
Tom

[jed the spread]

I think it best to ignore negative comments in particular ones that don't contribute..the last comment made was very personalised towards Neil (axeman) and the right thing to do would be to E D I T/delete it. maybe Rod can do his magic..

Hang on a minute.... You were talking about having to scrap your van and I was encouraging your project onward (Oh and his name is Rob not Rod if you want to PM him to get any of my posts deleted). I did comment regarding the engine sticking up a mile and you having to chop lumps out before you offered it up to find out yourself, I would have thought the time I took to post that would have been helpful contribution for you and although its not what you wanted to hear and you see it as negative, it was true. I tell you what mate, good luck with the rest of it and the poor mpg you will achive.....

jed

[carpmaster]

From reading all through the thread, then I think you've done well with this, despite some of the negatives thrown at you. A perfect world, it aint!

Good luck with it

Doug.

your right there Doug..thanks for looking
Tom

[carpmaster]

I think it best to ignore negative comments in particular ones that don't contribute..the last comment made was very personalised towards Neil (axeman) and the right thing to do would be to E D I T/delete it. maybe Rod can do his magic..

Hang on a minute.... You were talking about having to scrap your van and I was encouraging your project onward (Oh and his name is Rob not Rod if you want to PM him to get any of my posts deleted). I did comment regarding the engine sticking up a mile and you having to chop lumps out before you offered it up to find out yourself, I would have thought the time I took to post that would have been helpful contribution for you and although its not what you wanted to hear and you see it as negative, it was true. I tell you what mate, good luck with the rest of it and the poor mpg you will achive.....

jed

Thanks Jed...your right i did get Rob's name wrong and i apologise for that an oversite on my part...i met Rob when visiting Aidan..nice chap

[ELVIS]

I was toying with the idea of doing a golf gti conversion and i contacted garyd about wiring them up, nice chap too. What swung it for me to choose Volvo was the engine itself...we own a family gti and i know how good they are, we've had it for over 10 years. the volvo engine is solid and indistructable...it will go on and on. services on the engine itself are simple and very low cost. As for perfomance it has a great torque range and 115bhp. i am on the understanding from a good source that the aaz would be disapointment to me if i drove it after experiencing mine..not sure what it would be like driving a van with a gti engine..perhaps i will link up with a member who's got one installed and have a go..


Tom

Drop me a PM with your number. Probably passing your way at end of week (i only live in Exeter) so your more than welcome to drive it and have a puch/prod, ask Qs, take pics etc

As for driving? Im not saying anything until you have driven it (other than it makes more torque with a 'better' torque curve than an AAZ (makes more early and for longer), performs better than me mates 2.2 NA subaru and gives same MPG as JX/AAZ when driven at same speeds as you would a TD.
No brainer IMHO.

Mines 2e bottom end, Garyd's old mk2head that had 0 miles on it after being rebuilt by him and mk2 injection system (oh and a mild road cam )

Drop me a Pm and your more than welcome to do naughty things to it:ok

[carpmaster]

I was toying with the idea of doing a golf gti conversion and i contacted garyd about wiring them up, nice chap too. What swung it for me to choose Volvo was the engine itself...we own a family gti and i know how good they are, we've had it for over 10 years. the volvo engine is solid and indistructable...it will go on and on. services on the engine itself are simple and very low cost. As for perfomance it has a great torque range and 115bhp. i am on the understanding from a good source that the aaz would be disapointment to me if i drove it after experiencing mine..not sure what it would be like driving a van with a gti engine..perhaps i will link up with a member who's got one installed and have a go..


Tom

Drop me a PM with your number. Probably passing your way at end of week (i only live in Exeter) so your more than welcome to drive it and have a puch/prod, ask Qs, take pics etc

As for driving? Im not saying anything until you have driven it (other than it makes more torque with a 'better' torque curve than an AAZ (makes more early and for longer), performs better than me mates 2.2 NA subaru and gives same MPG as JX/AAZ when driven at same speeds as you would a TD.
No brainer IMHO.

Mines 2e bottom end, Garyd's old mk2head that had 0 miles on it after being rebuilt by him and mk2 injection system (oh and a mild road cam )

Drop me a Pm and your more than welcome to do naughty things to it:ok

I will take you up on that ELVIS thanks..fun times ..i will get mine going first and give you a shout. we can compare sizes then
off to do a bit more today (weather dependant)..refinements to the initial install..going to trim the gearbox support plate and now Aidan has given the freedom to experiment i will be modifying the petrol rubber mount. always worth a try. Other issues are the nuts on the engine/bar support rubber (blue) mounts..the nearside is a pig to tighten up..(not able to get a tool in there)...i plan to post some flicks of how things look at the moment..

catch you later

Tom

[Cableguy]

Intersting Reading mate.
With regard to height, my van has a raised engine lid of about 4 inches.
Rock n roll bed fits with no problem. Don't know where it came from, but I use a piece of 4 inch foam on top of the raised engine lid and that gives me a nice, flat and comfy bed.
good luck

[carpmaster]

Intersting Reading mate.
With regard to height, my van has a raised engine lid of about 4 inches.
Rock n roll bed fits with no problem. Don't know where it came from, but I use a piece of 4 inch foam on top of the raised engine lid and that gives me a nice, flat and comfy bed.
good luck

Hi thanks for looking, i'm glad you find it an interesting thread. I am not expecting too much trouble with height..i know i need to make a raised lid and i have a good idea on how to approach it.
Tom

[carpmaster]

Hello..
I planned to visit the van and carry out a few tweeks. First job I did was to mod the petrol rubber mount..

holes drilled and ready..

As promised a few flicks before starting the tweeks..other than sticking the carb back on.



A flick of the cv/drive shafts and engine supports.


loads of space either side..soon to be filled up!!

The part of the cam cover touching and the space available to me when i need to change/access something.

[carpmaster]

Now for the tweeks..I began with dropping the gearbox slightly so i could take the support plate off..I needed to trim part of the fin. doing this will allow the rubber mount do its job. at the moment the engine and gearbox are a little tight, hense the camcover toaching. hard work cutting the piece out..hacksaws..good tools and G clamps musn't forget them.

not the best pick..but here it is mounted..

the holes on the chassis i was discussing. i am using ..far left x 2..miss a set..next set x 2..

a different angle of the cv's mated to the gearbox..looking fresh..my little bit of Porsche "bling"

[carpmaster]

Before i could tighten up the rubber and its' mount..i needed to concentrate on the engine bar. i was having trouble tightening a nut on the nearside support mount. The first step was to loosen everything and lift the engine. I needed to shift both engine and gearbox to the right..approximately 10mm..by doing this i would achieve a tight nut fit,and, at the same time line up the gearbox support mount central (i havn't tightened it up yet..so allowed to move)...I unfastened the offside engine mount on the block and got to work.

mod done and stuck it back on..gave the engine a little tug to the right and over she went..

a climpse of the nearside..before the bolt was tucked under too far.

[carpmaster]

Richard...Dented Devon mentioned about the differences in petrol and diesel rubber mounts..here is the evidence..the holes on the petrol line perfect compared to the diesel..it would mean a difference in height. I opted to use the petrol rubber mount..thanks Aidan


Here is the baby set and looking at home..job done and really pleased

The result of carrying out the tweeks..i did have that feeling..i knew what to do..your right Ian (silverbullet) if you learn you will prevail..
no more touchy touchy

just to finish off..i managed to fit the nuts no probs..checked the alignment of the gearbox rubber mount and all was good..went for the final tighten..job done



thanks for looking
Tom

[carpmaster]

Hello again..

Just come back from a lovely holiday in Cornwall..Deerpark Forest..log cabins and all things natural.....lush

Before i went i spent a couple of days pottering around. I started with joining the clutch pipe...i used one of these fittings from brickworks...not sure if i have done it right...i slipped an olive on each end, added the brass fitting and tightened both sides. i have a sneaky feeling that i might have done this wrong. i cut the ends of the clutch pipe flush and fitted..without flaring the ends.. wasn't sure if i needed to do it with the brass fitting i had..i presumed it would work under compression and the olives would act as the flared ends..hope i make sense..not easy trying to explain this ..but a picture paints a thousand words...please tell me if i have done it wrong. i might have to replace the whole line..but i would be looking at replacing it in sections and i would much prefer to do it at a later date.(access etc.) the current line looks like steel, so the unification of the clutch line from steel to copper probably wouldn't work anyway.. i am sure your observations will help guide me to the right decision..



I then got to work at modding the cold start cable, i wanted to use it for operating the choke...i was quite chuffed with its operation once i had fitted it..may need a slight adjustment when eventually i get the lump started..take a look at these..

another view and you will notice the throttle cable has been fitted to the throttle body...

the throttle cable at the pedal end is prooving to be an absolute pig to fix and get right..spent several hours trying to sort it..so when i press the accelerator it fully opens the throttle..still got to sort this..had to down tools before i fell out with it big style...not the easiest place to access and the instructions refering to fitting it the pedal end are not that easy to understand..wish i could remember how it was fitted before..because of the difficulty in dismantling the old throttle cable...i am sure i will overcome this hurdle and plan to have another fresh attack on Monday.
Taking a step back, i decided to look at the thermostat housing and the hose connection..i tried every angle possible for the section of pipe to fit and it looks like i have hit another problem. no matter what approach i make the metal thermostat housing and hose section won't work..space, angle, finished height to allow the 6mm expansion pipe to do its job etc, etc. I am resigned to the fact i have to modify the thermostat housing. i plan to have a piece welded on it allowing it to bend/flow away from the back of the van and incorporate a tapped/spiggott on the crown of the thermostat housing itself...hopefully i can get this sorted soon..i have a contact at work that will be able to help...this is what i am up against...

thanks for looking..i will keep you posted..hopefully the weather will hold up on monday and i can get the throttle cable sorted. I can do other jobs..main coolant pipes..exhaust..establishing a home for the battery..look at the set up for the air filter..still plenty to do..
Tom