Club 80-90 Forums

I thought that perhaps it was due time i made some sort of journal of my van. Two reasons really. Its nice to have something to look back on and remember and it is an exceptional way to ask o whole lot of dumb or less dumb questions without clogging up the rest of the forum

Well... this is about what i had to start out with

A 14" vw caravelle syncro from 1985 with an aan gearbox and rear lockers. I payed a sum equivelent to about 800 punds for it and i travelled to an island outside of landskrova to get it on a trailer and haul it home.

Always liked offroadvehicles and was planning to some day build a baja or something just as bad when i found this on the web..
Thinking vw? 4x4? And felt I really NEED this.

So whats happened since then? Well... Not much really because i already have a project.


A heavely modified BeachBuggy wich i decided to have done before i started with the bus.
But over the time it stood there i ran across parts and items that had such a good price i just couldent let them pass me by.

A Wrecked legacy with a 2,2 l engine complete with harness and everything else i needed. 50 pounds +the gas and trailer to get it.

a set of seats for 10 pounds

a set of lt mirrors for about 50 pounds.

And now ive gotten it into my head that im supposed to have it running to sweden rock 2013
(Read RUNNING not finished)

but I have palced an order with RJES and im guessing the parts will be on their way soon (as if there isnt a TON of other work to do.)


dropped the engine

the gearbox, wich I already posted some about. About that I have decided, since it works. Itll just haveto run untill i can afford to buy or find a whole drivetrain with the finishgear to work better with the larger wheels.
I also dropped the fueltank and this is what it looks like behind


although its still alot better than i feared... though when starting to cut around rust Its ALWAYS alot worse than one might think. So in the end... Its probably Exaktly as bad as i first thought

Thats the tearing down part..
The actually productive parts are


"liftkit" for the rear. 30 mm nylonspacers.

Had a bit of rust here.. Well the whole part of the springplate on the trailingarm was more or less desintegrated. I did have plans to just switch the whole arm but insted i decided to fix the arm in place just to save time and moneys.
And to do that i first had to make a tool to press the plate

wich i then welded a piece of tubing with a lid on.

and then welded the whole place after some cleaning with a wirebrush on an anglegrinder and some zinkspray onto the trailingarm

(i guessing it doesent have to be better than this?)

also fabricated a set of "liftkit" for the front. This might not be so important to the whole RUNNING part but it does need to look a bit badass aswell.

Never got this to work though.

Had the whole front dicessembled but never got it togeather Cause of a confuzing Bush/guide/pipe


however we jiggled, pulled and twisted we just couldent get the shock through the whole.
Max and Caddy tipped me to -give it a wobble with a screwdriver..will come away. AND -Looks like a new one would be a good idea to!
Any tips or links to where i can find this small and annoying piece of metal to replace the rusted one with?
Anyhow we screwed it back togeather and shuved it out of the garage again since the weekend was over and the workshop is needed for work during the week.

Excellent work there , good on you for making the die for the arm plates, the on ly ones we have off the shelf are flat and this is not an ideal way to go.shall follow your progress
mm

Holy moly, do you realise how much those front spacers are going to lift your van?

Good to see another build thread ! Lift kits , im thinking extra stain on the CV joints here

actually... i can honestly say that i have no idea of how it will lift i just made it higher than the blueprint

and strain on cv:s? probably.. they must hold up to some lifting? Im thinking its not very extreme with around 40-50 mm.. or is it?
i do wanna switch them for the 930:s or 16" versions so maybe Im unintentionally making them brake?

might be ill machine the front spacers to a more agreable hight but i really do want it a bit higher. looks a bit goofy at original hight.

sow. How about those Spacers/tubes/guides on the front shockstrut. where can i buy those?


also, im building brakes with audo components

If your spacers are around 50mm you will get something like 70mm (or maybe even more) at the wheel.

If i remember correctly its commonly thought that 30mm is just about the maximum possible without other problems starting.

i will correct

Half of that rubber top is supposed to disappear inside of the under side of that front spacer too



Jed

so the centerhole in the spacer should be big enough for the rubberboot to go inside?

scitter wrote:so the centerhole in the spacer should be big enough for the rubberboot to go inside?

Yep...

It all looks a bit narrow to me.

Jed

im trying to find a place wich Handles all the parts i need to reseal the tank and that also has the ss tankstraps.

im in need of the plastic breather thingy 251 201 311B (broke one removing the dry tube)

and might aswell replace the gromets and the sender unit gaskets (VC.251.919.133)

and the stainless tankstraps. And here is the big one. id really like to order them all from the same place but im having trubble finding a place with them all.
Anyone who can help me out?
Need new Bush/guides/pipes for the front shocks

I found out that the place that had most of the gear i needed is berndt in Germany.

Was with the buss today and after pulling it into the garage today and being able to keep it there till the january 1st I started to clean it up a bit under the rear.
Guess you guys always clean under there? Bet there was about a few kilos of dirt, sand, Even rocks and shiet. I had cakes thick like 4 cm ontop of the upper springthing
(the box of sheet metal that the rear spring connects to)

and the beams were all full of dirt aswell. It REALLY is a wonder it isnt more rusted than it is. Water getting into that dirt and staying there. Should be nothing left but its actually quite good.
Have no idea what the germans did building this thing but i hope i succede just as well with the rustproofing later on.

Any ideas on solving the problem out there? Cant be good with this many holes all over and everywhere for the dust and debris to enter? I understand that all of them cant be filled since that would be even worse but some might be filled so roadcrap dont get into the beams as much?

this one is a bit closer to home for you
http://www.vw-shoppen.dk/product_info.p ... cts_id=379" onclick="window.open(this.href);return false;

Your rust


Reapir plates are approx 2mm for outer section, 1.5mm for the inner doubler (yes, there are 2 layers)



Inner doubler repaired and painted



Outer repaired


Best to cut off the tank crash-load support frame to see and get at the rust (can weld it back later)

The whole repair here on 80-90 Wiki (yes its all been done before ) ...

https://club8090.co.uk/wiki/Ar ... oss-member

Tank Straps, save your money...

It isn't difficult to repair your own tank straps unless they are completely rusted to pieces, the only parts you really need are the doublers at each end, particularly the two rear connections (which never rust too badly)... Plus some 2" strip steel, they won't rust again if they are painted sensibly, saves another £50 ish

Pictures following:-