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1.9 TDI Tin top van from INDIA
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narendra.vw
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Joined: February 07, 2013
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Location: Bangalore India
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PostPosted: Sun Jun 16, 2013 4:38 am    Post subject: 1.9 TDI Tin top van from INDIA Reply with quote

Hello to all the forum members! I officially became a member few months ago. I have been following this forum when the page was 715. This forum has given me so much confidence to rebuild my van. ( where I live, there are hardly any people who own vans. I find absolutely no parts in a scrap yard.). I had to import any part that I needed.
The following is details of my van when I had bought it in 2011.
1990 model, 1.6 TD 5 speed Tin top RHD
now it’s converted to 1.9 TDI(ALH)
I have complete details(photos as well) of progress in changing the van from 1.6TD to 1.9TDI
If you’re not tired of seeing one more engine conversions, I’ll will upload mine.
To all you Tin top owners, the following photos are some minor changes I have made in my van which might interest you.

bellow passenger seat box. mine is RHD

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hand brake easy to reach. pointer shows OE position

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all I need to extend the rod.Have done it. It works fine
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Sliding door auto catcher open & power locking.

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Contact point
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Switch shown is to open the sliding door catcher from driver side .I have one in back row seat sorry no photo of it.
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Hinged lid

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Middle seat bottom space

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Golf MK1 tail lamp replacing van tail lamp

OE look
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MK1 fixed
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Development
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insyncro
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PostPosted: Sun Jun 16, 2013 4:50 am    Post subject: Reply with quote

Welcome aboard.

I like the MK1 lights and use of wood on the dash Exclamation
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BugChit
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PostPosted: Sun Jun 16, 2013 5:27 am    Post subject: Reply with quote

Hey Nice work..
WoW, can't imagine trying to find or having to ship parts into the country for every little fix or change. Geeze, It's tuff enough for many of us here in the States to find a parts Van in a scrap yard. Also can't imagine the shipping cost and delays or delivery nightmares obtaining parts via out of your country.

Good Luck. and Keep us updated.
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joseph928
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PostPosted: Sun Jun 16, 2013 5:41 am    Post subject: New to Samba Reply with quote

Blue Bay Bus Welcome, cool van and yes post your build we never get enough VW info! Very Happy
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1987 syncro westy tin top sun roof , GW2.3, rear locker, decoupler, Gary Lee tire rack & winch mount, lift, south african grill, big brakes , rhein alloy ,15 BFG AT, Fiamma 10 foot awning ,140 watt rear 85 watt front solar , mppt, truckfridge, automatic fire extinguishing system, tencent oil cooler, And a RMW SS exhaust! - 1971 bug convertible 1776 engine- 2010 Subaru turbo - 1993 Toyota 4x4 truck - 1999 Harley 95 CI, big bore, Andrews cams . Also 80-84- vans. Stock 65 sunroof bug.
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ewalt98
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PostPosted: Sat Feb 01, 2014 8:34 am    Post subject: Reply with quote

Nice van, I like your ingenuity.

Lets see some more pictures!
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shadetreetim
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PostPosted: Sat Feb 01, 2014 7:20 pm    Post subject: Reply with quote

Welcome and thanks for posting. You've done some neat mods.
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Doing my best every time I drive it to dispel the myth these Vanagons have to be slow!


'89 Vanagon Bluestar/Country Homes 1.8T & .77 4th
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narendra.vw
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PostPosted: Sun Feb 02, 2014 6:07 am    Post subject: Reply with quote

Thanks to all who have appreciated my work. ( Sorry for late response.)
I do have done Electrical Power steering conversion & R&R bed in my own style.(All documented). Since I am new, being in middle of Gaints I am little hesitant.
Bit of EPS Unit
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Bit of R&R Bed. Now my van is 5 Seater & 2 Sleeper.
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Please let me Know if more Details needed. I can come up with seperate Thread. Thanks.
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syncroserge
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PostPosted: Sun Feb 02, 2014 9:51 am    Post subject: Reply with quote

narendra.vw wrote:
...being in middle of Gaints I am little hesitant.


Giants !? So many here shy away from the ALH at 50 degrees because of the oil pan...
You are a giant in your own way...

I want a picture of that oil pan for my collection Very Happy
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Zeitgeist 13
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PostPosted: Sun Feb 02, 2014 9:57 am    Post subject: Reply with quote

I like the innovations. I've been thinking a lot lately about how to engineer a split rear bench, which would be way more functional. Keep those pics coming
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Volkswagens powered by Volkswagen
'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender VR6 -->2.5 TDI?
Oly Bulli
'87 300TD OM606 7mm Myna pump and HX30
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tclark
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PostPosted: Sun Feb 02, 2014 7:42 pm    Post subject: Reply with quote

hmm I though ALH would not go under the engine cover
What engine mounts ?
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DAV!D
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PostPosted: Sun Feb 02, 2014 8:14 pm    Post subject: Reply with quote

Nice work with your mods.
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narendra.vw
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PostPosted: Mon Feb 03, 2014 6:16 am    Post subject: Reply with quote

syncroserge wrote:
narendra.vw wrote:
...being in middle of Gaints I am little hesitant.


Giants !? So many here shy away from the ALH at 50 degrees because of the oil pan...
You are a giant in your own way...

I want a picture of that oil pan for my collection Very Happy

Thanks , your words will boost my confidence.

Some visuals of oil pan you asked for.

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I was lucky to have a Good welder. Zero oil leakage.
Care to be taken, Oil pan should be clean from any oil or dirt.Dry as possible as it can be. After first welding grinding is a mast.Rewelding should be done & also look out for blow holes.
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Tried some stange Ideas. Heat resistent transparent 8 mm plate to know oil level. Later, got scared & put back the OE plate
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narendra.vw
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PostPosted: Mon Feb 03, 2014 6:29 am    Post subject: Reply with quote

tclark wrote:
hmm I though ALH would not go under the engine cover
What engine mounts ?


I will. Here we go,

OE 1990 5 Speed TD engine Mounts & OE bracket. I Do have routing of air Duct.
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Hump on the Lid is 1" thick. Ground clearence from Oil Pan to Ground is 9".

Please let me know how to multi quote. Thanks.
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bluefirefly
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PostPosted: Mon Feb 03, 2014 8:24 am    Post subject: Reply with quote

Great job, I really like your van and all the mods you did to it.
Please, could you post more details and pictures (when you have time of course) of the dash cluster mods (speedo and tack) as well as the electric power steering.

Thanks and keep up the good work!
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onemat
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PostPosted: Mon Feb 03, 2014 9:06 am    Post subject: Reply with quote

Hello Narenda and welcome.
I too like the unique things you have done to your bus.
Please tell me what the "joystick" and flip up switch on the dash is for.
Regards,
Matt
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MarkWard
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PostPosted: Mon Feb 03, 2014 1:21 pm    Post subject: Reply with quote

Hello. I have an ALH in our Vanagon as well. My pan looks a little more homemade than yours. I notice in the picture it is welded just below the mounting flange as well? What was the reason for that? Here is an adapter for the oil pan that requires no welding. Not sure how to buy one though. It is pretty neat. Nice job finding mounts that could be adapted. Mine are all custom fabricated. Only thing stock is the carrier bars and they have been cut and modified too. Thank you for sharing.

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narendra.vw
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PostPosted: Mon Feb 03, 2014 8:37 pm    Post subject: Reply with quote

Zeitgeist 13 wrote:
I like the innovations. I've been thinking a lot lately about how to engineer a split rear bench, which would be way more functional. Keep those pics coming


a.Thank you Zeitgeist 13. Since Details carry photos app 20 in no/-, I will upload by weekend.

b. Thanks David.

One small request, please bare with me if Iam late in responding.
1. Time Difference.
2. Iam still a Desktop Guy. Very Happy

I will answer regarding Joystick, dash cluster mods & Oil pan tonight. Thanks.
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narendra.vw
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PostPosted: Tue Feb 04, 2014 8:54 am    Post subject: Reply with quote

onemat wrote:
Hello Narenda and welcome.
I too like the unique things you have done to your bus.
Please tell me what the "joystick" and flip up switch on the dash is for.
Regards,
Matt

Now,I feel like I'm part of the family. Thanks for asking.

Front Hot air circulation was pre fixed to Wind Shield & Floor circulation.
Front Dash dummy vents were used in following way. (Please Note:- Van has OE Roof AC).

Right Vent.(My van is RHD).

When delivered to me.
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Coustamised to my requirement.
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Now operational. Red toggle switch used for Starter button. (Very useful for VW owners. All VW owner know that engine can't be cranked twice. Key has to be bought to off position & try again. This may be temperamental in traffic. This is where press button will comes to use also OE Switch contact points life will increase).
Note:- Unit is supplied with Relay. Relay fixing is a most.
Right switch used for Sliding door catcher opening.
Blue Toggle switch used for momentary temp sensor grounding cutoff , if ALH engine starts late. (As of now mine seems to be OK).
Extreme left, Self returning Switch is for extra pair of Horns.
Bottom ‘Double pull switch‘. Most interesting.
First pull, Extra white lamp comes on. (100w Each). Second pull Extra Lamp goes off but will be connected to Main Bulb High Beam. When High beam is switched on all four lights comes on. Go to low Beam extra lamp switches off. Push the switch all the way back to switch off the Extra lamp.
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Horn location,(Bosch Chrome Grill. Been with me for 20 yr’s).
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Zeitgeist 13
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PostPosted: Tue Feb 04, 2014 9:03 am    Post subject: Reply with quote

Do you have any other pics of the front of your van? I'm particularly interested in the small round lights next to your turn signals
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Volkswagens powered by Volkswagen
'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender VR6 -->2.5 TDI?
Oly Bulli
'87 300TD OM606 7mm Myna pump and HX30
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narendra.vw
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PostPosted: Tue Feb 04, 2014 9:23 am    Post subject: front view Reply with quote

Yellow ones are Rally 2000. White Hella ones came with the van OE, was fitted on the Bumper which I relocated. Size similar to Hella 500. All carry 100w each.
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