1.9 TDI Tin top van from INDIA

[narendra.vw]

My last post has stayed the same way, unlike my work. It has progressed.
Further Update,
Parts fabrication, Minor correction & Finishing touches were done. Later Parts were galvanized to prevent rust.
Progressed visuals,

Shifter parts puzzle.

Semi solved puzzle.

Parts fitted onto the GB, puzzle completed. Van’s cross member does have a hole for selector cable to pass through.
For the Gear shifter lever cable, the hole was made wider to align with shifter lever. This avoids cable bending(Arrow shown).

Modified cable shifter lever with connected cable(Stretched OE ball shifter).

If you wish to retain the OE ball shifter lever, weld a flat measuring 2.5”L, .75”W, .25”T at the back of the shifter lever(Couple of photos back should give you an idea). Flat bottom needs a 8mm hole for cable connection.
Something to think about:-- If the cable is not connected, the welded flat will not come in the way of OE rod type shifting, This Mod makes Cable shifter or Rod shifter interchangeable without removing the OE ball lever.
After competition of the Shifter fixtures, unit was fitted onto the Gearbox. Momentarily OE Ball shifter was replaced with my cable shifter lever. I tried operating the shifter unit’s Gear lever using shorter cable( Shifter unit was placed on the ground floor).Gear shifting worked effortlessly. So, my was 16:9 wide.

Some crucial points considered in this project.
Weight transfer of the fabricated unit( GB side) distributed evenly .
No fatigue on GB bolts(4 bolting points on GB used).
Perfectly aligned parts making moveable parts less wear & tear.
Easy access for cable fitting & adjusting.
Avoid cable bends so that the cables are not stressed.
Mig welding so that no snapping of parts.
Parts used will have zero maintenance.

The most important work is over. I hope rest should be formalities.

Work to be done,
1. Positioning & fitting the Gear shifter unit near the Driver side(The most Important).
2. Cable extension to meet the 8’+ length requirement(Should be an easy work).
3. Making of shorter stroke Gear shifter lever(Optional).

Please let me know if I have overlooked some points. Thanks.

[TequilaSunSet]

You have some serious skills!
_________________
Don't harsh my mellow...
1985 Hightower Vanagon 1.8T- Gone
1972 Panel Bus- Gone
1967 Bug- Gone
1964 Euro Sunroof Bug- Gone
1969/72/63 Sunroof Bug- Gone
1975 Brazilian Bug in the Philippines 🇵🇭- New to me

[tschroeder0]

ha, you started this thread worrying over your skill, you are a monster! very nice work sir.

[narendra.vw]

[narendra.vw]

[narendra.vw]

Gear Stick Shifter Unit work progress.
Unit placement details.
Unit will be fitted below the Van’s floor(Behind the OE unit position).

Following details should clear your doubt based on my unit placement decision.
Advantage on placing the unit below the Van floor.
1.The shifter cables will be in line of sight with GB until they reach GB.
2.Unit needs no attention once the cable is connected(Let’s Say, fit & forget).
3.Stick’s pivot point is the only part that is visible above the van’s floor.

Disadvantage on placing the unit above the Van’s floor,
1.Unit will eat up the van’s floor space.
2. The cables will run on the floor at least 18” before it disappears below the floor.
3.Cable routing will have bends at few places(causing strain on the cable).

Preparing the unit fixtures for it’s fitment onto the Van or should I call it ‘marriage‘?
I spent some time with the unit thinking about it’s fitment. Finally I decided to use unit’s OE mounts.
The rear two will be used without any modification. Front two will have minor repositioning.
I made sure to use unit’s rubber mounts. By doing so, any kind of vibration to the Gear stick is eliminated.
Later, stick will be repositioned to my requirement(Needs heating & hammering process).

Visuals.

Four mounting points. Front two mounts repositioned.

Mounting Demo. Spacer Bushes carrying M8 thread. Arrow shows unit’s OE rubber mount. Basically, unit hangs bellow the Van’s floor with four threaded bushes bolted on both sides.

Short stroke(Minimize Gear stick moment), how it’s done.
Change the pivot point on the shifter stick by increasing the Gear stick length, bellow the pivot point within it’s limit.
I’m going for it.

Visuals,

Extending stick’s length bellow the pivot point by app 10mm(Arrow shown). This should reduce the Stick’s stroke moment by 20%.

Closing all the gaps will dustproof the unit(Bit of sheet metal work is done).

later unit’s base was hammered(marked area) to make way for the extended lever movement.

I did operate the stick with the cable attached using different angle just to make sure it’s not obstructed by any part.

For further work, I need to put the van on to a lift or on the Ramp.
By doing so, I will get better access to work below the van.
Since van will be stranded for at least a week, future work needs to be planned.
I’m bit busy with my Daughter’s admission to Engineering degree. Still can’t believe she opted for Mechanical branch.
So, It will take a bit longer for me to be back with more updates.

My completed Air scoop Mod post next week, just to keep things flowing,
Thanks.

[narendra.vw]

Air Scoop Mod & Air filter repositioning.
Expecting,
1.Air scoop, more cool air to the air filter & Inter cooler.
2.Air filter repositioning, reduction in air sucking noise & clean, cool air to the Turbo inlet .

Scoop air inflow open area measures 1.25”Tx 6.5”H .
Sheet measuring 6.5”Hx7.5”L removed from the Van’s left rear corner where the Intercooler is located.
The cut van’s sheet was strengthened by bending the sheet inwards app 5mm. The back part was completely U bent. This allows scoop’s projected sheet to slide in & self lock.


Air Scoop Mod & Air filter fitting visuals,

Body cut open for the Scoop …………..Scoop ready. Arrow shows, the projected metal sheet slides into the van’s back cut part & locks(Later front two nuts secured the scoop).

Scoop was completely hand made. Not me , done by a skilled sheet metal worker.

Air filter’s Part no/-- ………………….……………………....................Air filter with MAS.

Air filter viewed from the van’s cut part(Sufficient gap between the Air filter & the Inter cooler can be seen).

AC water drain pipe is seen on the left.

Air filter to Turbo, plumbing details.
Air filter out ………………………………...........................................Turbo in

Later, Vacuum pipes & wires were tidied up.


Unscrewing the Air filter clamp(Method to remove the Air filter).

This method helps in securing the Air filter from theft to some extent. Air filter removing is possible only through scoop’s cut opening.

Air scoop finial fit(Left Side indicator is moved slightly back).

Top OE Scoop & bottom Scoop will have small holed mesh. Helps in stopping the water droplets from getting into the air filter.

Sorry, no performance parameters(Van doesn’t have any fancy dials).
Van needs to clock some continues Highway miles to note the changes in performance.

No progress yet with the Stick shifter unit.
Icing on my Van next,
Thanks for viewing folks.

[narendra.vw]

Icing for my van
I had my mind set to have a DVD with surround system. In this segment very few companies had 5.1 option unless we use additional component to convert to 5.1.
Googled & narrowed it down to JVC-- avx77(too expensive), and another unbranded.
Took the risk to go with the unbranded one.
The Deck feature:-DVD,32GB USB port/SDHC card, FM, Hi Fi(Similar to Home Audio), AUX Audio/Video in, copper coated body, built in 5.1 processor & lastly 90$ tag tempted me to go for it. Presently it’s sold out.

The down side ,
1. Made in China(One thing to appreciate, they know what we look for).
2.Unit needs 6Ch Amp for the 5.1 audio to work.
3. No Bluetooth(I ‘m relaying on Navigation unit).

My choice, in visuals,

Deck, single Din 5.1(New) Edit: The RCA & AV cables are flexible. No space conjunction behind the deck.

Slim ¾”T & light weight 10.1” Roof Monitor(New).

JBL 4Ch Amp(New)…………………………........................custom bracket.

4Ch Amp fitted inside the Dash. Space utility . Pic was taken at an angle bellow the Dash. Amp dimension 13“L x 8“W x 2”T

The Amp brings life to Front speakers with Tweeters, Center speaker & Subwoofer.

My 15yr old 35+35watts pioneer Amp. Stuck it with 3M inside the dash

The Amp brings life to rear Speakers.

For Front Door, JBL 5 ½” speakers & On dash my old JBL Titanium tweeters.
Rear, one year old 4 ½” 45 watts RMS each speaker.

Centre speaker Pioneer TS-CX900(New & expensive)………..My 15yr old Bazooka takes care of sub woofer job.

Finally, I was able to fit all the components within the Dash.
Van’s floor is clear of RCA Cables & speaker wires.
Bass was set to mid level due to speaker’s wattage limit.
Audio is good in low, mid & high volume. Clear Audio sound, no distortion.
FM signal receiver is very good(A small wire can do the antenna job).
I'm yet to fit the Monitor & check the DVD performance(Monitor wiring is done). 5.1 works only with DVD.
Presently, I am enjoying the Audio.

Update with the performance video once the Monitor is fitted.
Thanks .

Monitor fitted. I was impressed with the outcome. PVR experience! .

360 degree Viewing & Recording.

My City traffic is becoming denser day by day. , Driving or parking in narrow places, I’m finding it more & more difficult. I had to do something about it.
I gave a thought & decided to use a technology that gives me some comfort. The technology should also help me in legal Battle.
Going through many combination, finally I ended up using following list of units.

HD Dash cam with AV- out option(help while climbing steep Hill).

Camera bellow front Door’s side Mirror(Mirrored type).……………Camera above Reg plate(Mirrored type).

Triggering Unit. Three AV- in & one AV- out to Monitor.
AV-1 acts as a default(Door Mirror), AV-2 first triggering(rear Camera), AV-3 last triggering(Dash cam).

Wireless Video transmitter for reverse camera(no lengthy AV cable).

Monitor display shows, working side camera.

Presently, Recording is for front view only .

[narendra.vw]

Cable shifter Mod update.

On web, I sourced a link, where they supply Shifter cables with different lengths. Yes, they did had a Cable which was suitable to my requirement.
Immediately, I dropped the idea of joining the two Cables to get my required length of 8’ 2”.

Followed it up by placing an order. Make- Auto Zone .co. The Cables are bit expensive, app 150$ for the two, including shipping cost. Due to this new development, the project cost will go up by 270$.
Untill the cables arrive from US, Project will be on hold.
I’m Looking forward for a feed back on these Cables(if any one have used it),
Link:-http://www.autozone.com/autozone/accessories/TCI-Auto-8-ft-3-in-stroke-shifter-cable/_/N-25zx?itemIdentifier=433175&_requestid=8953491
Mean time, my in use Mod.

Rock & Roll bed.

During my work, I noticed the van’s OE middle row seat gathering dust in a corner(Van Middle row seat was replaced by two bucket Seats). Since, I had seen visuals of R&R bed in Westy, I set my mind to make one.
A week later, I started working on the design. I couldn’t get any working design in terms of dimension (it’s the most important). Tried studying some visuals available on the internet.
Made a prototype using my old jeep’s back bench seat. It operated as planned. However, a bit of correction was necessary .
Got the courage to implement the same on the Van seat.
Fabrication work started. Edit:-- Neither a single hole drilled or a single part was welded to the van’s body.

Visuals

Third Seat separated & cover,foam removed...…...... Frame was carefully matched & welded. Hinge was fabricated by using the cut material of the seat frame(Recycle ).

Found a sweet spot in terms of Sitting angle, Proper thigh support & Stretching length. (Under the covered plate lies the ECU unit). On a side note, the wooden floor badly needs protection…….....2 Work almost completed. Pic does not do justice to the amount of brain work gone into it.

When fully stretched, over all length measures 74”. Sorry, not for someone beyond 6 foot.

Positioning & determining the length of the lever is very important. The paired levers are not of the same length.(Needs some trail & run Concept).

[IdahoDoug]

The 74" measurement in that picture cannot be correct. From the rear hatch to the front of the seat edge in my van is barely 72". Are you in a Vanagon?
_________________
1987 2WD Wolfsburg Vanagon Weekender "Mango", two fully locked 80 Series LandCruisers. 2017 Subaru Outback boxer. 1990 Audi 90 Quattro 20V with rear locking differential, 1990 burgundy parts Vanagon. 1984 Porsche 944, 1988 Toyota Supra 5 speed targa, 2002 BMW 325iX, 1982 Toyota Sunrader

[luVWagn]

Nice camera setup, love it. I want to do that into a raspberry pi or nexus 7.
_________________
'91 Syncro 16 Reimo Hightop Conversion, eTDI

[IdahoDoug]

Wups - nevermind. Just realized that orange line DOES go all the way to the rear hatch. I thought it ended at the rear of the seat bottom cushion. Carry on!!

DougM
_________________
1987 2WD Wolfsburg Vanagon Weekender "Mango", two fully locked 80 Series LandCruisers. 2017 Subaru Outback boxer. 1990 Audi 90 Quattro 20V with rear locking differential, 1990 burgundy parts Vanagon. 1984 Porsche 944, 1988 Toyota Supra 5 speed targa, 2002 BMW 325iX, 1982 Toyota Sunrader

[narendra.vw]

Thanks.luVWagn.
More option on Triggering Unit .
The last triggering AV3-In can be used as per the Camera location. Front viewing from Side (Indicator triggered), inside viewing, under body like suspension viewing or L/R cross road viewing.
An additional single Channel DVR, in-between triggering unit’s AV-Out & Monitor’s AV-in, any trigged Camera can be recorded. DVR cost app 66$.
Folks, did you figure out how a Dash cam AV-Out will help in climbing Uphill.

IdahoDoug, an additional 1”+ is gained when the cushion is replaced back(R&R Bed).

R&R Bed Fabrication continues,

The unit was removed for final weld, grinding of rough edges & painting. My fabricator did a good job(Arrow shows the ‘Stopper & Guider for the stand).

Stiffeners added for strength. Position 1, Stand supports the seat when stretched. Position 2, Same stand will restrict back rest movement in seating position………...After paint job & before assembly. Seat mounting bracket,seen on the pic Right(bracket will be bolted to either side of OE seat mounting point).

Cushion & Seat cover going back to their respective frame. (matching Seat Cover will be stitched later.)

All parts were fastened by using M8 (8mm dia) half thread High tensile bolt, Self locking nut & Washers so, there’s no loose ends. Special Grease used at all the moving parts……....Cleaned all the mess before fitment.

Work was then complete. Unit worked like how I imagined it.
More to come……

[Emmitt]

[narendra.vw]

[narendra.vw]

R&R Bed, last posting.

Going back to seating position.

Lift the Bottom seat a bit to fold the stopper/stand bellow it. Press the edge of the Bottom seat lightly & start pushing it back…..The unit automatically comes to seating position & Bottom seat’s stopper/stand guides back on to the mounting cross member lock.

The whole operation takes less than 10 sec to complete.

Important note:-- In the seating position , the Occupant’s weight is transferred to Mounting cross member & Rear body mount. No stress is experienced by the levers.



All set for a week end trip to the mountains. Van roof LED‘s lighting the rear. Picture taken without the Flash.

My observation on this Mod,
When the Van on the move with two happily dozing, the centre & the side hump gives a good grip & secure feeling. Couples may not like this setup.
Cushion along with the springs, lines up with body contours unlike the hard Base(Plywood).
The R&R Bed Mod allows the Van to have a Five seating & a Two sleeper on the move
Lastly, a slight Back rest play when locked in the seating position.

Yet again, I have reused Van’s old part which got me a R&R Bed + empty space at my work place.

Mid row with Modified Bucket seats.

OE Mid row Seat frame was modified to fit two sliding type Push back Seats(Donor, Toyota MPV).
When the seat frame is reverse fit (facing the rear seat), the slider comes in handy to gain leg space.
I have used Donor’s Driver side Railings. Gives me more sliding & locking option!

Visual Details

Mid row, occupied by two Sliding Push back Seats………….A very unique simple mechanism was Designed to the slider lock so that it could be unlocked by operating a lever attached to the lock releasing mechanism at the back of the seat(The odd looking knob was replaced).

The system helps the rear passenger to self unlock the Mid row Bucket seat slider lock & push it forward & get a better access to come out.

Self Designed mechanism to unlock the Seat slider(By pulling the cabled lever, both the locks get unlocked).

Utility Drawer, Fabrication details.

The Drawer & it’s locking unit is quite strong, can’t be Broken that easily. The Heavy duty slider has ball bearing which makes sliding much easier. When locked there is no rattling or any kind of annoying sound.

If you were wondering what happened to OE rear seats(Pic taken at my farm house).

Yes I know, seat badly needs a new cover.



R&R Bed Mod concludes.

The Thread loves to see the count of left hand Colum go up. Thanks.

[61Scout]

Great ingenuity Narendra! I love how you just dive in and go with your ideas. Your build is a great example of what can be done with a lot of hard work and perseverance. This is certainly one very custom van! Thanks for sharing and posting. I look forward to seeing/reading more about your build.

Kevin
_________________
1986 Westfalia Weekender Wolfsburg, RJE 2.3
1985 Tin Top, Subie 2.2 + 5MT
Floppy Mirrors no more: http://www.thesamba.com/vw/forum/viewtopic.php?t=653018&highlight=
Remove the front spindle nut with ease: https://www.thesamba.com/vw/forum/viewtopic.php?t=679567&highlight=
Remove the rear wheel bearing housing without messing with the big 46mm nut: https://www.thesamba.com/vw/forum/viewtopic.php?t=679507&highlight=

-Nec Spe, Nec Metu

[narendra.vw]

[luVWagn]

Narendra, come to Seattle area, work on my TDI please
_________________
'91 Syncro 16 Reimo Hightop Conversion, eTDI

[narendra.vw]