Club 80-90 Forums

Mark brought van back on Friday so on with a few more jobs.

Have not been able to find any second hand pushrod cover and exhaust tin for passenger side of engine so decided to fab some up. When find some decent second hand items will then swop them over.

Removed items required from my van so I could make templates.


Two panels from my Autosleeper.


Template made for cutting of plate.


Plate marked out before cutting.


The fabricated item next to original. Think this cover as well as protecting pushrod tubes aids cooling? Hammered a couple of ribs in plate to give it a bit of stiffness.


Original exhaust shield with template made up.


Plate cut off template before shaping.


Exhaust tin completed with original. Made this in two pieces. Tacked welded rear section. Plate was not long enough to make out of one piece.


Fabricated items painted up.


Original two from drivers side also shown with two fabricated items.

Will fit these tomorrow when paint dries. Will replace these fabricated panels if or when I find decent second hand items.

Painted bumper brackets and fitted ladder to rear door.

Mark - Think you still have the plastic corner section for the bumper?

Nice bit of metalwork there Jeff. Have you tried (Roger?) Holmes near Thirsk for the original bits Tel 01845527447

Getting near the end now.


Rear tailgate ladder and bumper now fitted.


Home made exhaust engine tin fitted.
Surprised at how fitting the two exhaust tins and push rod tube covers has reduced the engine noise.

Only a few jobs left now.

Inside. Table leg sockets and mounting brackets for legs.
Outside. Ariel, trim to seal to hitop.

As Mark was taking the van when I was away on holiday I bottled out of fitting radio ariel? Found out when Mark returned van he has also done the same? Done a nice job of fitting radio but no ariel? Looks like I will be drilling new paint work at weekend.

Van is then ready to sell on if Mark decides not to keep?
Will be taking down to Harewood House in a couple of weeks and may stick a for sale sign on.

I'll be interested to see how you drive both your vans to that one Jeff!! We're bobbing down on the Saturday in the van so will pop and say hello!

Thorgills wrote:I'll be interested to see how you drive both your vans to that one Jeff!!

Easy you are driving one over for us!

Looking fab

All jobs about tied up now following bits & pieces done this weekend. White board list nearly clear.


List down to two jobs now.

Mark to finish sorting out internal wiring.
Seals to hitop roof?
Two wheels trims still to sort.


Looking to get some PVC channel to seal front and back of hitop roof. Anyone know where I can get from?


Table leg sockets painted and fitted also remounted table legs.


New ariel fitted now have radio.

Now might try and get some use out of my van before the summer disappears.

Now crunch time for Mark - Will he or wont he take it on as his???????

If had not rebuilt my engine last winter would be tempted to keep this myself.

Mark you know you want to ..... !!!

Great work, it looks brilliant.

Looking good excellent job

Regarding the high top seal, and after reading some of MM's threads, you'd be far better off sealing it with sealant rather than the knock on edging, that stuff just seems to let water in and trap it in there, undoing all of the good work you have done

Having seen this van in the flesh and now that the paint has settled a bit I can honestly say that is one tidy van!!! I'd be surprised if Mark doesn't take it on but I understand his comments about knowing the van he has now and how good it is!
Top job fellas!
Now, about mine.......

Completed final job on Komet which has been annoying me since it was put back on the road. OIL LEAK from pushrod tubes.
Purchased expandable replacement from VW Hertitage. Had tried to seal round the tubes when we first got engine running. This did slow it down slightly, but I could not stand the drips on my drive and every time I parked up having to set the drip tray.


New tube.

After removing pushrod shield confirmed that leak was between front two tubes. Went with the front tube as this had a few bad dings in it.
Removed rocker cover, rocker shaft then pusrod. Pushrod was a squeeze getting past water pipe which runs along left side of engine.
Then flattened original pushrod tube and cut with tin snips.


Removed tube.

When pulled tube away had a shower of oil from block so had to jack up left side of van to stop flow. Lost about 1/2 litre before flow stopped.
Cleaned up seating faces for seals and applied smear of grease to new seals which came with tube.
Seated block side of new pushrod tube and compressed tube and it popped into head seat.
Refitted push rod. On setting up pushrods and making sure seated in block noticed number 3 head sealing ring was distorted and sticking up into head? No leak from this area but may have cured this in my earlier attempt with sealer.
Decided it needed doing so placed order for second tube.
Fitted rocker shaft and cover and took for run. Great leak now cured.

Second tube turned up on Sat morning so went through same process again. Only took about 3/4 hour. So now should have a drive free from oil stains.


Two new tubes in position.

Mark also spent a good afternoon cleaning inside of wheelarches and applying coat of underseal. Good job done before salt starts appearing.

Have now clocked up 1300 miles since back on road and also used the van for a couple of weekends away. As Mark cannot decide if he wants to keep this van as a runner I am going to test the water now and place it for sale on this website. Anyone interested send me a PM?

Mark must be mad (well, madder than we know he is ). But his van has been with him for some time and I suppose there is some merit in knowing your van inside out.
Seriously, that is some van. I'm sure whoever gets it is going top be mightily pleased. Many congrats on a job well done.

I agree - but when ever did our heads rule decisions with these vans? A great tidy van.