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1.9 TDI Tin top van from INDIA
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pinetreeporsche
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PostPosted: Wed Jul 01, 2015 8:13 am    Post subject: Reply with quote

[quote="BugChit"]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.



But on the other hand I bet a really good mechanic or welder only charges a few dollars per hour, as opposed to near $100/hr in the US or Europe. Well, northern Europe--- the southern tier is likely getting cheaper, esp. Greece.
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narendra.vw
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PostPosted: Wed Jul 01, 2015 8:39 pm    Post subject: Reply with quote

pinetreeporsche wrote:

But on the other hand I bet a really good mechanic or welder only charges a few dollars per hour, as opposed to near $100/hr in the US or Europe. Well, northern Europe--- the southern tier is likely getting cheaper, esp. Greece.

Thanks, You are spot on. They are skilled & versatile too. luckily, they do exactly as I tell them to do(sadly, I'm left with the last generation). Things are getting stiffer here too.Laughing
Edit: Any more guesses on the pic shown. Wink
I like to revel it by week end.
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narendra.vw
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PostPosted: Sat Jul 11, 2015 9:15 am    Post subject: Reply with quote

Time to revel the ‘Tool‘ before it looses out. Before that, I like to thank all for your thoughts & the reply.
I presume picture failed to give out much to get the right Idea .
So, let’s solve it together.

Some History before solving the Puzzle.
History,
My experience & the reason for this project.
We all know that, most of the VW vans comes with a Side sliding door. Robustly built to go the distance.
Operating the door from out side(opening or closing) is easier. A young teen can handle it.
Once inside the rear passenger( he or she ) trying to close or open the door needs a real effort(being a expert in gymnastic or Yoga will help Smile ).The closing is more challenging.
More frustrating is when you have to get down from the driver seat & go all the way around to do the chauffer Job.
Finally, I decided to bow to ‘Mother of invention’. Necessity is the key word.
Yes, you got it right, ‘Power sliding door‘(PSD)!

Unit semi assembled(Reversible motor & C channel track).
Image may have been reduced in size. Click image to view fullscreen.


Thread progresses with your thoughts.
Thanks.
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0cean
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PostPosted: Sat Jul 11, 2015 1:17 pm    Post subject: Reply with quote

Popcorn
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Cluster Rebuild:
http://www.thesamba.com/vw/forum/viewtopic.php?t=569920&highlight=

Left for Dead the Resurrection Story Build:
http://www.thesamba.com/vw/forum/viewtopic.php?t=613669
(Number of Different Donor VW Vans Body Parts Used: 12)
(Number of completely different vehicles parts used: 3)
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markd89
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PostPosted: Sat Jul 11, 2015 9:38 pm    Post subject: Reply with quote

I bet when you have your design finished, you could make and sell a kit for this Very Happy
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narendra.vw
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PostPosted: Sun Jul 26, 2015 11:09 pm    Post subject: Reply with quote

markd89 wrote:
I bet when you have your design finished, you could make and sell a kit for this Very Happy

Thanks Mark. The Project is more of a ‘Do it yourself’ kind.
All you need to do is,
-Dismantle your son’s old Bike.
-A visit to a motorbike scrap yard.
-A good electrical knowledge(two way connection, relay etc).
-A close friend who’s having a Machine shop.
Yes, bit of time dedicated to the Project.

The Project did not make much buzz !!??

PSD Progress continues…
A few days passed, studying working mechanism of Japanese van’s PSD.
The mechanical, electrical & electronics are too complicated & needs lots of modification to incorporate those into the van.
Here, my main aim was not to spoil the van’s originality. The unit fixture attachment should be a bolt on which can be removed without harming the geometry of the OE.
My mind was set to over look some safety feature as long it was within the limit.

Few more days passed as Info on PSD started filling my PSD folder. Once, the Info I got was encouraging I went ahead with the project.
First, I started of with the concept & turned it into a Design.
Design, after going through different parameter, it was time to make the design a reality.

Took me another few days to finalize the parts required for this project. Simplicity & cost factor was the main object.
Some parts needed an external work(for a week, Machine shop was a second home to me Smile ).
After few hiccups the project was completed.

How it Works,
-Working procedure is very similar to Power window(PW). PSD Motor has initial torque(momentum needed for the Door to close & self lock).
The door needs to be 70% open to gain momentum to self lock after closing.
-‘Power unlocking door latch ’ which is being used from the day one will be synchronized to the PSD(Details in the beginning of my thread).

Work pending,
Tiding of the wring system by adding Solenoid, Switches & Relays.
-Out of two switches, one switch will be a wireless remote & the wired switch will be Dash mounted(reachable to the Driver). PW switch is being used for the Dash. Both switches do the same operation.
-A reversing Solenoid Relay for the Motor.
-a Solenoid(pulling type), to release the Door slide stopper hook(a must, when the door starts to close).
-A bit of finial touches to the track channel.

Safety,
1)Regarding safety, I’m going to follow the same theory followed for the unmanned railway crossing, Stop - look & proceed.
2)The engine switched on & the brake pressed, Van’s wireless Central locking takes place automatically. Due to this, PSD switch doesn’t work unless the Centre locking is unlocked. One of the important safety feature.
finally, due to Safety issues, I opted out of single press auto close operation(It can be done).

PSD working.
I’m longing to show a video of PSD working but at the same time I’m also waiting for an electrical part from US( Reversing Solenoid Relay). The part will complete the wiring loop.
I’m in two minds, weather to show the working of PSD by directly connecting to the battery or wait for the part.

Until than,
A Geometry home work to your ‘Inside out‘. Smile
Image may have been reduced in size. Click image to view fullscreen.


Seeing is believing, next…
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newfisher
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PostPosted: Mon Jul 27, 2015 7:31 am    Post subject: Reply with quote

Im in. Having a PSD would make my wife happy
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dobryan
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PostPosted: Mon Jul 27, 2015 8:45 am    Post subject: Reply with quote

Can't wait for the video. Applause
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'87 Westy w/ 2002 Subaru EJ25 and Peloquin TBD

"To travel hopefully is a better thing than to arrive." Robert Louis Stevenson

MD>Canada>AK>WA>OR>CA>AZ>UT>WY>SD
https://www.thesamba.com/vw/forum/viewtopic.php?t=620646

Building a bus for travel in Europe (euroBus)
https://www.thesamba.com/vw/forum/viewtopic.php?t=695371

The West Coast Westy
https://www.thesamba.com/vw/forum/viewtopic.php?t=746794
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AndyBees
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PostPosted: Tue Jul 28, 2015 6:01 am    Post subject: Reply with quote

I've been following this Thread for a while. Nice build!

Narenda.vw, adding the Jetta Cluster makes it a master piece with everything else being icing on the cake! Very Happy
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narendra.vw
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PostPosted: Tue Jul 28, 2015 8:11 am    Post subject: Reply with quote

Thanks. newfisher
Yes, with these kind of small comforts, wife will be wife for life. Smile

Thanks, Dave O
I like to present the video with impact.

AndyBees wrote:
I've been following this Thread for a while. Nice build!

Narenda.vw, adding the Jetta Cluster makes it a master piece with everything else being icing on the cake! Very Happy


WOW, thanks Andy.
One or two points, I like to give you the Credit. ‘What‘, is kept secret. Wink


I’m hoping for the part to be delivered as early as possible(I’m eager to show you all).
Thanks.
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narendra.vw
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PostPosted: Sat Aug 29, 2015 11:08 pm    Post subject: Reply with quote

This weekend, the most disappointing weekend for me. Sad
After receiving all the parts, with confidence I fitted the unit to the door.
Before the electrical connection, I directly connected the motor to the battery to check the track alignment .
The closing of door worked perfectly. My smile gone when the motor couldn’t open the door. The initial angle of the door where the motor needs power to over come that angle, which the Motor doesn’t have. In fact the wires started to get hot. Once the door is straight it works fine.

On the trail run, I had not closed the door completely. My mistake.

For the records, I have used a Honda scooter starter along with a bike sprocket attached to it(bit of machine shop work).

As of now, I had enough of this project . My brain is drained of. If someone wants to push it further, I can give more details of it.
Just showing the Video of door closing, I feel it’s not appropriate.

Motor & track attached with a strengthen angle piece. 1 & 2 are the two hinges used. A must.
Image may have been reduced in size. Click image to view fullscreen.


The wiring circuit designed for this project.
Image may have been reduced in size. Click image to view fullscreen.


I do have a Video which may make you Smile (a small request, keep the audio volume low).
https://www.youtube.com/watch?v=j4CiiHxC-XQ
The locality you see in the video is where I stay for almost 30 yrs.
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newfisher
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PostPosted: Sun Aug 30, 2015 8:49 am    Post subject: Reply with quote

What about a TDI gear reducted starter motor?
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allann
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PostPosted: Tue Sep 01, 2015 8:16 pm    Post subject: Reply with quote

narendra.vw wrote:

Never experienced any heating problem with or without ac. Coolant level was always maintained. Never felt the need of condensation tank .Every bit of TD coolant hoses were used .
More details? Please let me know.

Hello from Lithuania. Starting my activity in forum with PM for You Very Happy Some time ago I have found Your story. Was looking for some information about fitting this type of engine in to my bus. Not much info. There are not so many crazy people like us who prefer ALH type engine vs AFN type, but looks I am the winner in this madness, as I am trying this with SYNCRO!!! Under the lid it is almost everything custom made Very Happy . Starting from pan, mounts brackets, custom made input ad output manifold and so on. Syncro ir taking some spaces that You had in normal bus. Everything is relocated... Maybe later I will start the story in the forum, but now...
Engine I have is not ALH but ASV(81Kw), they are the same in consruction. My story is lasting for about 3 years and I do not see the end Laughing . Now I came to point, there I have to know how the cooling system will be done. I have some hoses left from old 1.6TD(most of them is not original, some in bad condition) and I have everything from my donor Seat Ibiza. The expansion tank will be from donor. As You told Your cooling is working without problems even in India Laughing I ned everything what You can tell and show.
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Oh, sorry... Somehow i have made post in Your theme instead PM. This trash can be deleted somehow if this is not in place. Anyway the question about cooling adoptation is very interesting. Sorry once more.
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goffoz
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PostPosted: Tue Sep 01, 2015 9:36 pm    Post subject: Reply with quote

Wow Shocked love to know more
please share.
start a thread Pray
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narendra.vw
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PostPosted: Tue Sep 01, 2015 10:54 pm    Post subject: Reply with quote

newfisher wrote:
What about a TDI gear reducted starter motor?

The motor is mounted so near to the seat bottom, any additional part will hamper leg space. As of now, I can use the unit for closing.

I’m taking a break from this project. Once I find a solution I will be back.
Any ‘inside out’ from your side, please let me know. Thanks.

To, Mr, allann
I’m surprised & happy to see Thread’s initial pages to be still alive. Thanks. Smile

Coming to your project, way to go on engine mounting, crankcase modification & exhaust system.
Try to keep as OE as possible. Any part used should be from VW family(single window shopping).
I loved the Crankcase Mod. Clean work.

Clarification,
-Van’s OE Engine & gearbox?
-What engine mount used?
-Right hand side Mount?
-Did you try TD exhaust manifold. Lot easier to work with.

Following are the few pic which I had posted in other thread. These might help you while doing the cooling system.
Almost all the TD hoses & clamps were used(no hoses were cut).
Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.

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Image may have been reduced in size. Click image to view fullscreen.


No worries about PM.
I’m sure all are eager to see your Thread. More Info in your thread. Good luck.
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allann
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PostPosted: Tue Sep 01, 2015 11:19 pm    Post subject: Reply with quote

Right side mount is made by me. Ruber mounts is from bmw, but vw t3 ruber mounts can be used too. Later i can post some photo.
I even did not think about TD manifold. Adapter for turbo must be fited. After all oil output from turbo is very low. Do not like oil what is in turbo after you stop the engin is going to both sides of turbo, especialy to output. You working part of turbo is new. Maybe you did'n notised anything bad. And i like to do everything the hard way Smile
About gearbox... Now i have to check the number. But its syncro gearbox from with dif lock and G gear. Front dif is with lock too. And i have made diskonektion of the front. Wire shift is made by me too. For sincro i was the first in this mod. There is no so much space fo shifting gear in sincro.
Engine was 1.6td and now it wil bee ASV 1.9 TDI 81KW.
Maybe you can take som shots of your cooling system and PM me. What have you done with pipe from wather pump and so on.
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narendra.vw
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PostPosted: Wed Sep 02, 2015 6:32 am    Post subject: Reply with quote

allann wrote:
Right side mount is made by me. Ruber mounts is from bmw.

Maybe you can take som shots of your cooling system and PM me. What have you done with pipe from wather pump and so on.


-Reference to your third picture, it appears that the gap between the carrier bar & engine mounting point is bit more than needed(effects engine centering). This gap may give problem later while aliening the Propeller shaft. I think, the excess gap is due to the BMW mount.
-The cooling system you are asking for already exists in the pics along with coolant flow direction. Pic opened in a different window will show more clarity. . Still if you need some particular angle let me know, I will pm to you.
- Expansion tank, I meant Reserve tank where we do the coolant Top up.

Once you come up with your Thread, there will be lot of replies for your Syncro Project(take my word, here Syncro has a special place).
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allann
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PostPosted: Wed Sep 02, 2015 8:11 am    Post subject: Reply with quote

It looks so, but... the aluminium bracket is moded too. It has hole for oem mount and another for mounts of bmw. For this job i have made some kind of jig. With this i was able to put engin in to the car even witout any mounts and it was centere as it shoud be. After was made holders for mounts, left bracket and so on. Centering is checked many times. OK, thanks for your attention. I have to find some time for my tread.
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narendra.vw
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PostPosted: Wed Jan 06, 2016 9:07 am    Post subject: Re: 1.9 TDI Tin top van from INDIA Reply with quote

Power sliding door update.
This will be my second attempt. having the new year support, I’m determined to complete the project. Smile

I decided to take care of the wiring section first. Reason being, whatever the outcome wiring can still be used to open the door latch or to unlock slider lock with a remote. This alone is a big relief.

Progress,
After a week’s of hard work wiring was completed.

As usual my work details along with the visuals.

Cutoff switch, first one cuts off power when door is closed. Second one when door is opened.
Image may have been reduced in size. Click image to view fullscreen.

This is a safety feature for the motor.

Center locking guns are used for Latch & Slider lock. First, door latch. Second, slider lock.
Image may have been reduced in size. Click image to view fullscreen.

For the slider lock, the gun is fitted inside the cabin with the cable linked.

More to come in few weeks time.

I’m also reworking on engine air inlet plumbing.
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Geosoils
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PostPosted: Tue Jan 12, 2016 1:35 pm    Post subject: Re: 1.9 TDI Tin top van from INDIA Reply with quote

Question about the electric power steering unit you installed. What is the brand and since i am in us. ill have to track down a source. Do you like the way it works
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