Evolution of my Eurovan Weekender

[bigfoot_ev]

[HeyCrutch]

[gesoffen]

[bigfoot_ev]

[HeyCrutch]

@bigfoot -- Great rack setup. Just curious ... does that rack & tire setup obscure your license plate at all?

I've been noticing lately around where I live (NC) just how many Tow Hitch bike racks completely obscure license plates. The various European racks made for the Eurovan are all designed to hold bikes above the plate - something I think is required and enforced over The Pond.

I would assume that in states like North Carolina where only a rear plate is issued, that the plate should either be visible in its regular position or relocated to an aft position of the bikes & rack when used, but I never see anyone doing that.
_________________
-2003 EV MV Wk - Forest - 51k
-2002 EV Camper - Ghost - 82k
-2003 EV GLS - Fluffhead - 176k

-1997 EVC - 12vVR6 (SOLD 5/2025)

[bcolins]

Excellent upgrades!!!

[bigfoot_ev]

Another van upgrade!

We got out camping recently to test out the addition, traveling to central OR and WA. These wheat fields sure have a nice view!

I added a Gary Lee rear hatch spare tire rack from evrack.com. I had a few reasons to do this.
- One, I wanted to have the spare more easily accessible instead of dropping it from below. Think about changing the spare while on rutted muddy forest service road.
- Two, and this came from an off-roading 4x4 van buddy. Imagine being way out off-grid enjoying life when you get a flat. Fine, I have a spare. Well as soon as you put that spare on you no longer have a spare. Best to head straight home and keep your fingers crossed. TBH, I don't find myself in those kind of camping locations very often, but at least now I have options available.
-Three, I now have space under the van for a larger diesel tank and more room available for a water tank, should the need arise. The diesel tank under the hood actually got warped, probably from the heat and the cap would leak ever so slightly. So, that needed a fix.

In this next photo I forgot how to van camp and brought too much stuff. I added a place to hold my tables to the kitchen cart and had 2 boxes full of stuff. When I got home I removed the table holders and everything fits into 1 box now.

The diesel tank sits in a custom holder bolted to the spare tire carrier. The white object up behind the tank is the new location for the heater pump. It is super quiet in this new location.

The tank slips out easily for refill and it has a quick release for the fuel line. Based on past experience, I will fill this tank once maybe twice a season.

Here are some rack close ups. First is how I travel around town, when not camping.

A look under the cover.

Here is camping mode. This most recent trip we stayed at multiple pack it in pack it out places so the 'trasharoo' knock off was very useful.

Of course you need to upgrade the hatch struts. In case you are wondering, changing hatch struts is very easy.

Here is something I always carry but don't use that much. A couple of tweeks by adding a small pizza stone and draping welding fabric over the top makes this work really well. Hot biscuits!

And a significant milestone for the van! Hehe, what this really means is I got a lot of fluids that need to be changed now.

_________________
2003 Westfalia Weekender, AXK, 01P

[VanGeek]

Brilliant! Westfalia & Winnebago folks are darn good at designing these sorts of things but surprised they didn't do the same in the factory versions!

[VeeDubn]

Lookin' good!

[bigfoot_ev]

Here's another one of those small but useful changes that I didn't know I needed until I lived in the van for a bit. During non-camping times having top access to storage on the sides worked just fine. However, when we are loaded up for camping we have bags that fit perfectly right on top of the access hatch. I even added special straps that hold the bags in place, right on top of the hatch.

So, another access was needed. Thanks to VeeDubn for pointing me in the right direction. I took the solid panels on the sides and with an addition from 8020, I turned them into sliding doors. Now I have storage access from above via the hatch or via sliding doors. I did the same update on the other side as well. Making changes never ends...

I particularly like I can easily reach my plumbing should a problem ever happen while on the road.

_________________
2003 Westfalia Weekender, AXK, 01P

[bigfoot_ev]

I got a winter project completed. I have now fully embraced having AC power in the van. For some reason I resisted adding AC to the van. Over the many years of camping in this van I think I can only count 3 times I used AC. I guess it's because we always pick non service campsites, or even better, dispersed camping. We will continue to pick non service campsites unless some circumstance comes up. But that doesn't mean I don't have access to AC in the van while camping.

The big motivator for me was to simplify how I manage AC charging for the 2 batteries on board, the start battery and the house battery. I finally got tired of dealing with 2 extension cords, one that went under the hood and another that went under the hatch. So the obvious solution is to drill a hole into the side of the van and add an AC power port. Connected to the power port is a surge protector with over current and over voltage protection. Since this project required a new built in AC charger I had to round out my Victron collection with a trickle charger. I decided on the IP65 12V 5A.

Adding the power port and connecting the 2 battery chargers required a new layout inside the van for the components and all the wiring. I moved the house battery charger to the driver side rear and then permanently mounted my inverter where the house battery charger was mounted on top of the battery. This is the AC power source for when we are either on or off grid.

For more details on the power port install check out this thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=754766

The way I configured this is to automatically charge the start battery when plugged in. But the house battery charger is on remote control so that it only charges when I want it to. This is important when maintaining lead acid and LiFePO4 batteries at the same time.

Here is my power port on the driver side rear quarter

New Victron charger for start battery

All the Victron components in one app

Updated wiring diagram

Unrelated to the AC upgrade but since I was tearing things apart, I changed my LFP battery heater. Now I can set whatever temperature I want to start heating the battery cells. This is really only useful when winter camping and I need the battery to stay warm and functional.

I think I might try using an electric kettle for the morning coffee. One less reason to light up a flame inside the van.
_________________
2003 Westfalia Weekender, AXK, 01P

[bigfoot_ev]

More camping additions! We just finished a whirlwind of camping trips. The main attraction was a 2 week trip up Vancouver Island to Port Hardy. Along the way we stayed at some new places that included Upper Campbell Reservoir, Woss Lake, Port Alice Link River, and Alder Bay. We got back home for a week then off to camp with some friends at Manchester State park near Port Orchard. I even got a backpacking trip in earlier in Sep using some of the van gear!

On our way to Vancouver Island we did our first parking lot camp. Can't say I'm a fan but the price was right, free. This is the 7 Cedars Casino. I'm not a gambler, we went for the special of the night...porterhouse steak.

First up is an old school idea that we forgot about but then revived. Cotton mesh shopping bags to hold fruit and vegetables. We take them into the grocery store and fill them with fresh fruit and/or vegetables. They then hang from the magnetic hooks. This does a good job keeping them from getting crushed and staying fresh.

We also discovered how to install a wine dispenser in the back. Works great!

This next picture has a couple of additions. We moved from my small no garage house in Seattle, where I had to keep my tools in various tool boxes, to our new house with garages. I could actually put tools into cabinets. Wow what a revelation. But now I had various empty tool boxes lying about. So, I repurposed a roller box to kitchen duty. Over 2 trips it has been refined. I think I like it but we shall see. When packed up I strap it in just behind the drivers seat. Just in front of the tool box is a Luminaid light. These are very cool lights and during a recent sale I bought more. Not only are they very functional but I like the companies story. It was a hit on the backpacking trip as well. If you're interested there's more info here: https://luminaid.com/. Next is the string light. I've never used these before but they work really well for ambient lighting. My particular version rolls up into a hanging light that has a battery and a small non-functional solar panel.

Of course, the string light I bought is already gone from Amazon. If you search for solar camping string light you will see many options. This is like the one I have.

Here is a new addition I really like. It is a collapsible fire pit. This fire pit burns wood very efficiently and it protects the ground underneath it. It includes an adjustable cooking grate. The version I have is made by CampingMoon and is the MT-055. Here's a shot testing in our backyard.

I went to the local hardware store and bought a 12 x 12 expanded steel grate. This holds charcoal up out of the bottom for a larger cooking surface.

Some action photos.

The entire package folds up into a slim carry case. A little heavy being all stainless but it fits perfect in the back of the van.

This is definitely a good addition. I'm working on a propane conversion as well. Living in the PNW we regularly have fire restrictions where the only allowed fire is a propane fire pit. I'll update when I get that figured out.
_________________
2003 Westfalia Weekender, AXK, 01P

[bigfoot_ev]

Tables, let's talk about how that has changed over the years.

The camp boxes that you see in the very first post (https://www.thesamba.com/vw/forum/viewtopic.php?p=10053076#10053076) always had a flat work surface. It seems you can never have enough flat surfaces to lay your stuff on when camping. That worked pretty well. I found an old picture with my first camp box boondocking with some friends. As an aside, there's the flip up table in the weekender but just this past weekend my daughter told me how much she hated that table. First it would hit her in the knees opening it and then pinch her fingers putting it away, geez kids.

After we got the teardrop I added a fold up table since I got rid of the camp boxes. It was nothing fancy, very generic and it did what it needed to do. But I didn't like how things slid around on the smooth plastic surface. That especially made me nervous when making pasta, flame on maximum, large pot of boiling water and things start moving. I made accommodations for carrying it. The boxes for the flat slide out were made so that the table fit on top folded up. When I moved to rear drawers, it fit on the very bottom and provided a surface when pulled out part way. You can see this in photos on the first page. Here's a generic picture of the table I'm talking about.

We were still using this plastic table up until very recently. You can see it in the post from last fall (https://www.thesamba.com/vw/forum/viewtopic.php?p=10135531#10135531). What changed is that I got a new camping addition that is stored in the spot the table used to be. I'll post about that soon. So, I had to rethink the tables. Rather than have 1 largish table I decided to have 2 smallish tables. And having just returned from a couple of weeks camping up Vancouver Island we are really happy with the new set up. From my test this past spring the little yellow table got some coats of polyurethane since it's a keeper. It is one of the first things that gets setup at camp along with the chairs.

This is now typical:

This is how we cook now. I bought this table specifically sized for where I store it, which is inside behind the drivers seat. Also, it makes a great drying surface. Another new addition is the battery operated pump also highly recommended. We use it for rinsing our hands and rinsing dishes. The sink inside the van would be horrible for rinsing pots and pans. In this picture we cooking some freshly foraged chanterelles. At one of our camp spots a forager shows up out of nowhere asking if we want to buy some chanterelles, hell yeah we do!

And when we are done cooking we migrate over to the small yellow table.

And of course, there is still the inside table which rotates outside if needed.

On this past trip we spent a bit of time under the tarp in the rain. This is how we make coffee in the rain. BTW, I still love this tarp especially when it's raining. It's large, it keeps us dry, and no drips into the doorway. I also love this pot and stove setup. These heat exchanger pots work really well and this stove is like a blowtorch. It stores in the pot wrapped in a kitchen towel. Hiding behind the propane bottle is a battery operated coffee grinder. After having a bad experience getting coffee from a 'specialty' shop we now take care of business ourselves. Super happy grinding our own coffee, then use a collapsible filter holder for pour over into the thermos. We've had that stainless thermos for many years and it still works amazingly well keeping coffee hot when it's cold outside.

_________________
2003 Westfalia Weekender, AXK, 01P

[bigfoot_ev]

[Endopotential]

I'm 5'9" and fairly limber, but even as a solo camper I have to be a bit of a contortionist to get up and out of that poptop. Especially with that headboard extension, it's a fair bit of futzing to get that drawbridge in place after I crawl up top.

I'm impressed how the rest of the world squeezes two people up there comfortably.

[IdeaNerd]

@bigfoot_ev: I apparently missed your 04/22 update of this thread! Some great updates there! Thanks for posting them.

And, for the record: I really appreciate this thread of yours. It's got some great "life" in it. Kind of a refreshing change for me from the more repair-oriented posts that sometimes come to dominate.

Those camp table legs are kind of a kick — a few aspects of their design are very similar to a projector stand I sometimes use as a portable standing desk in the field.

Apart from that, I have a couple of folding bamboo tables I'm really pleased with. I'll see if I can post those here soon. Pretty neat design, that folds up tightly into a rectangular shape which in turn fits in a nylons a bag. The entire set up process is just unfolding in and clicking things into place, rather than actually having to assemble anything. (I have a bit of a collection of portable tables, as it's a product design space I'm interested in.)

I also really like your information dock setup. I want to build a center console for our van at some point, and may incorporate some of those functions and connections there, along with some sort of snack table. It looks like you have modified your console area some as well, but I don't recall seeing details about that earlier in this thread. I do see it poking its head in a picture or two earlier though. It looks interesting. Can you share more about it?

@endopotential: Love the lights, and hadn't thought about how the foil would bounce that light around. It does look quite cozy and bright! I may do some experimenting with that. We use fairy lights quite a bit outside our van, usually running off a USB battery back — I'm fond of their gentle lighting.

@all: If memory serves, a few different enthusiasts here have done something akin to @endopotential's extension board for the upper bunk. I've had thoughts of doing something similar plus perhaps some low-profile storage trays up where the pool noodle is in the photo above. My question is this: has anyone come up with a design yet that they're pleased with, that works well for two people upstairs rather than just solo? (i.e. entering and exiting separately at times, without overly-disturbing the other person.) I'm curious.

[bigfoot_ev]

[Endopotential]

You guys are inspiring me to tinker on my '02 Weekender some more.
Next on the docket is my coolant system and crack pipe.
I cringe a bit though, as every project I get to seems to trigger a different set of problems. Hopefully no more burned out ECUs at least.

@Bigfoot_EV Being a weak California, I also had trouble with it being too cold up in the poptop. I've been surprised how well a cheap thin foil layer helps to insulate things.

And what did you use on TorquePro to get transmission temperature? I seem to recall only two "engine temp" options. One tracks with the radiator temp; the second I'm guessing must be transmission, but it doesn't correlate with the analog meter I had hardwired into the transmission plug itself.

Let's see if this link works

[bigfoot_ev]

It looks like I have been forgetful about updating this thread with various things I have done this past summer. This is a good place to document, should it ever be necessary to show the evolution. I also have a camping update which I'll add a little later.

First up is the LiFEPO4 battery and charging upgrade. I built a 3.4kWh 24V battery, added a Victron DC-DC charger, Victron AC-DC charger, and Victron battery monitor. I detailed the battery build and charging upgrades here: https://www.thesamba.com/vw/forum/viewtopic.php?t=792426

Next I wanted to see if I could improve and therefore extend the life of the timing chain components. I tackled this by trying to remove oil sludge from years of following VW recommended oil changes at 10k miles. This is an ongoing process and I'll continue to document progress here: https://www.thesamba.com/vw/forum/viewtopic.php?t=793624

Then came the fix for foam blowing out my air vents. The Samba forum has a lot of good info documenting the process. I added my 2 bits here: https://www.thesamba.com/vw/forum/viewtopic.php?p=10257817#10257817

While tearing the dash apart I had to fix an airbag dash light on. I discussed that here: https://www.thesamba.com/vw/forum/viewtopic.php?t=793884

I also repaired and repainted my A pillar trim pieces. I pretty much followed the same path as VanGeek did using fiberglass cloth and epoxy resin: https://www.thesamba.com/vw/forum/viewtopic.php?p=10196562#10196562. I painted them with HT-400 Dove Gray. I'm really happy with the 'new' look.

And finally, a preventative work on the steering angle sensor PCB documented here: https://www.thesamba.com/vw/forum/viewtopic.php?p=10281328#10281328

_________________
2003 Westfalia Weekender, AXK, 01P

[bigfoot_ev]

I finally got out to do some testing of my ever evolving camping needs. The major test was about our sleeping situation. We only sleep in the upper bunk of our Weekender. Before, the only upgrade I did was to add a couple of backpacking air mattresses. These are slim and light which is fine because I used them on top of the standard upper bunk pads. I would then throw a circa 1998 coleman flannel lined double sleeping bag on top. The extended trip last fall really exposed some shortcomings. The major issue was that the sleeping bag does not fit up above with the top down. So, we had to blow up the mattresses and set up the sleeping bag each night. Then, when it got cold the ole flannel bag didn't cut it.

I found a couple of killer deals on the run up to xmas last year and bought a Kelty Tru.comfort doublewide sleeping bag and a Klymit double V sleeping pad.
Here's a link to the Kelty bag: https://www.amazon.com/gp/product/B0BRQQPTNS
And the Klymit pad: https://www.amazon.com/gp/product/B07YP8JVG5

Next, I removed the OEM bunk pads, put down some 5/8" work out pads cut to fit, then the Klymit pad, and then the sleeping bag. This all fits great with the top down. But what about comfort? The bag is awesome. Two people can regulate air flow independantly and there is a pillow compartment to keep them contained in the bag. The Klymit pad is also really nice. We have no issues with elbows or hips poking through moving around. Ultimate sleep comfort is still a work in progress. The Klymit pad air needs to be adjusted to get exactly what you want. I'm happy to keep this setup for a while.

Another sale item I got last winter was yet more camp chairs. I still like the old chairs but my laziness wanted something easier and quicker to set up. This really became apparent when we were setting up and breaking camp daily for weeks at a time. So, when I saw Frontrunner chairs on sale I jumped. When collapsed 2 chairs fit perfectly in my rear storage drawer. The Frontrunners only take seconds to set up (or collapse). I'm very happy with these.

Another idea I wanted to test was a small mobile table. I found some generic camp table legs on Aliexpress for $22. I reused an old piece of plywood, cut it to size, and then painted it with leftover paint from my conversion. Below is the table with the frontrunner chair. Oh yeah, wifey got a new rocking chair.

Here is what the legs look like. There are many generic choices on Aliexpress.

And I've been playing with this setup for a bit so I thought I would show you what my driving info looks like. From the top, we use an Android head unit that supports CarPlay for directions and mapping. Below the head unit is a wireless charge pad in the cubby. To the left is my OBD II reader and a voltmeter for the house battery. Below the OBD II reader is my Fire tablet with Torque. Inside the Torque display is trans temp, coolant temp, average MPG, instantaneous MPG, distance to empty, and start battery voltage. Someday I'll upgrade the tablet to one that has GPS so that I can use more Torque features.

Finally out camping again!
_________________
2003 Westfalia Weekender, AXK, 01P