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1.9 TDI Tin top van from INDIA
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specialev
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PostPosted: Sun Nov 30, 2014 9:21 pm    Post subject: Reply with quote

Very nice. A lot of fine engineering on display here!
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narendra.vw
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PostPosted: Mon Dec 01, 2014 4:44 am    Post subject: Reply with quote

specialev wrote:
Very nice. A lot of fine engineering on display here!

Thank you. specialev. Your appreciation fills my Energy drink.
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240Gordy
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PostPosted: Wed Dec 10, 2014 11:33 am    Post subject: Reply with quote

Very interesting thread, many interesting mods and pictures

Cable shifting mod is interesting.
Most beyond my skill level

Take care
Hope to see more
Will be watching for updates
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narendra.vw
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PostPosted: Sat Dec 13, 2014 11:22 pm    Post subject: Reply with quote

I’m sorry for the late reply, just wanted to add some spice to the post before posting.
Thank you 240Gordy,
My views,
Every one is skilled in his own sense.
Spicy Update on shifter cable;

Yes, yes, the wait is over, I Just received the shifter cable(A big hug to my niece). Very Happy
1.Shifter cable along with more goodies. A spare Clutch plate(228mm), compressor, Rear Bilstein Shock Absorbers(HD) & Bazooka 300W
Image may have been reduced in size. Click image to view fullscreen.

Old 1990 M year Shocks will be replaced immediately by Bilstein HD.

2. Showoff(resent forest venture pic near my farm). Smile
Image may have been reduced in size. Click image to view fullscreen.


Project will not resume before Christmas & New Year celebration(family get together).
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luVWagn
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PostPosted: Sat Dec 13, 2014 11:30 pm    Post subject: Reply with quote

Will not resume, or will NOW resume? Smile
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narendra.vw
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PostPosted: Sat Dec 13, 2014 11:50 pm    Post subject: Reply with quote

luVWagn wrote:
Will not resume, or will NOW resume? Smile

Project continues from next year. I need to change the coolant of my brain. It's heated up Laughing Laughing
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narendra.vw
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PostPosted: Wed Jan 07, 2015 7:36 pm    Post subject: Reply with quote

Let this Year 2015, keep You all in Top Speed / low rpm. Smile
I once again thank you all for the Inspiring comments.
luVWagn, Thanks for the eagerness.

Shifter cable Mod,
Snail pace progress.

New Cable details.
The new Cable rod thickness(5mm) & the previously made adapter thread didn’t match. So, I had to revisit the Lathe shop.
By careful measurement, the new Cable rod guide’s Sleeve & rod length were customized.
Patience is the key here. Any slight mistake, and the Cable is as good as a scrap.
I made sure, the gear lever stroke length & selector length unchanged.

One week is over for the completion of such a simple work. Time flies.

Shifter cable M5 threaded rod on the Left……… Shifter cable M6 threaded ring on the Right………….. Adapter bush with matching threads on the either side, right in the centre.
Image may have been reduced in size. Click image to view fullscreen.

Same goes to both end of the Cables.

A modified stopper plate(GB side) for the new cables to fit in. Cable clamps useful for body mounting.
Image may have been reduced in size. Click image to view fullscreen.

Clamps found in the lathe shop(cost-0$).

A bit of uncertainty on the New Cables.

New cables(unknown to me) itself is a uncertainty.
New Cable rod thickness is less by 1mm in comparison with shorter shifter cable rod thickness.
The Cable strength???
Cables are non lubricated. Should I lubricate it or not?
On a positive note,
The product is meant for the 4 wheeler’s Gear shifter.
The background of the Product marketing company seems to be reputed(Autozones.com).
the cable moment is 100% better than my old cable. The most Free cable moment I have seen.
The finished Product quality is beyond my expectation.
Please, someone enlighten me on these Cables.

First stage & mid stage is over.
The project last stage, fitting off the Shifter unit.

For further Shifter work, van needs to be on the ramp for a week. I hate to see my beast on a ramp. Crying or Very sad

Some excessive thinking for you. Wink

Self designed folding, sliding & rotating user friendly Table.
Meant for the Front & the Mid row seats. I need a royalty from you folks. Laughing
My thoughts, the additional sliding option makes it much easier to use. Your thoughts?
Fabrication details.
MS steel pipe dimension details.
1.5” dia x 9” L sleeve with 2mm wall thickness.
1” dia x 17” L pipe with 2mm wall thickness.
1” dia x 3” L sleeve with 2mm wall thickness.
¾” dia x 21” L pipe with 2mm wall thickness
Plywood 13” x 21” sheet with ¾” thickness.
2” x 8” L, 1/4th thick flat for Body mounting.
Make sure , the sleeve wall thickness is min 2mm.
Hardware, two M8 thread knob, nuts, wing bolt & wood screws.

All the above dimension are as per my requirement. You can change the dimension to your requirement, but make sure the pipe slide in & out of the sleeve freely.
Also see to that, there is no play between the sleeve & the sliding pipe. Visuals should give you a better idea.

Visuals (remember my van is a RHD).

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


Absorb the T vertical, it has an angle app 30* at the top. The angle takes care of the of the Front seat’s back rest contours.
Image may have been reduced in size. Click image to view fullscreen.

Three + one’ way compatible. Fourth, is for the external use. How? Smile

Surprise, surprise.
Table on the Bubble, irrespective of van’s parked angle details & finished Table fabrication work details in my next post.

Until then, these pics to keep you in company(sorry no CAD).
Image may have been reduced in size. Click image to view fullscreen.


Yet to find a time slot for the van to be on the ramp.
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insyncro
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PostPosted: Sun Jan 18, 2015 8:48 am    Post subject: Reply with quote

I am working on a cable shifter as well.
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narendra.vw
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PostPosted: Sun Jan 18, 2015 8:58 am    Post subject: Reply with quote

Thanks. I was feeling lonely, but not anymore. Please do share your mod. Good luck!
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insyncro
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PostPosted: Sun Jan 18, 2015 9:03 am    Post subject: Reply with quote

I will when completed.

Thanks for the inspiration.
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narendra.vw
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PostPosted: Sat Feb 14, 2015 9:59 pm    Post subject: Reply with quote

One more Cable shifter Mod. It’s a confidence booster for mine

Cable shifter update.
The Project has hit a minor Road block. The new Cable’s overall length is not what it claims to be. It’s 2” short. I’m bit disappointed. It affects the gear stick positioning. Most importantly free arm movement(long term shoulder fatigue).

1.Gear stick position as per my design. 2.Gear stick position moved back due to new Cable shorter in length. Your valuable opinion appreciated.
Image may have been reduced in size. Click image to view fullscreen.

Keeping the originality as close as possible, minor changes has to be made in the Shifter unit.

No feed back yet on new Cables! so, my focus on new cables has changed .I have decided to rework on the design. The new design will incorporate both the cables to be adaptable(old or new).

1.Old & new Cable adaptable Design. The Design will allow the shifter unit to regain 1 inch.
Image may have been reduced in size. Click image to view fullscreen.


Removing few bolts, the Cables can be replaced(old or new). GB & the Shifter unit linkage is undisturbed.
‘Old’ refers to the linking of two shorter Shifter Cable to makeup the length needed(my initial plan)..

Please let me know if I can go ahead with the new Cable.

Table Mod end results.
Small observation,
-Table tilting height has to be kept under +/-2“. Beyond that the Wing bolt will lose it’s alignment.
- Greater Van angle, you’ll start feeding your ears. Wink Smile
- Easy Table movement even while seated.
- 13mm ring spanner a must to adjust the leveling of the Table
Work Details.
Explanation with visuals.

All parts were Powder coated & given some glamour Smile
Image may have been reduced in size. Click image to view fullscreen.


1. M8 Threaded rod of the Slider pipe inserted into the pre drilled hole of the wood. 2. The M8 threaded Bush lever’s inside face was coated with a sealant. 3. The bush was placed into the cut portion of the wood & screwed. The Slider pipe then rotated 360* till the gap between the pipe & the wood narrowed down to app 4mm.
Image may have been reduced in size. Click image to view fullscreen.


1. The second lever was bolted on to the right side of the Slider pipe. A point was marked on the wood through the slotted side of the lever. A 8mm hole was drilled into the wood. A M6 threaded Bush was hammered into the wood which will be used by the Wing Bolt. 2.T vertical finds it’s place.
Image may have been reduced in size. Click image to view fullscreen.

The unit is ready for the van’s Table mount.

Table mount fitting details(made sure van was parked on a level ground).

Since, Van had a Modified Utility box below the passenger seat, access to fasten the mount with bolt & nut was possible.

1)1”flat with a 6mm hole at the top along with a nut welded(useful where hand or the tool are not able to reach). 2.Carefully holes marked & drilled(paint scraped for proper sealant bonding). 3.Sealant used on the mount‘s surface(once it dries up it turns into rock solid).
Image may have been reduced in size. Click image to view fullscreen.

Edit: Made sure the Table was parallel to the van’s floor before drilling the holes.

1.Table mount, fastened onto the Body 2. Mount cover press fitted.
Image may have been reduced in size. Click image to view fullscreen.


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


Table at rest, 2. Self lock option for Mid row(centre) & front (L/R) seats.
Image may have been reduced in size. Click image to view fullscreen.


Table in check with the van’s gradient angle.
Image may have been reduced in size. Click image to view fullscreen.


This concludes Table Mod details.

It’s so much satisfying, when the out come is every bit of your imagination.
I hope, my Utility Table project was interesting.
Thanks.
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EL31415
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PostPosted: Sun Feb 15, 2015 2:19 am    Post subject: Reply with quote

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tjet
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PostPosted: Sun Feb 15, 2015 6:06 am    Post subject: Reply with quote

These taillights look good.

Anyone have the OEM part #'s?

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

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narendra.vw
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PostPosted: Sun Feb 15, 2015 7:19 am    Post subject: Reply with quote

Thanks, EL31415.

Mr, tjet,
The tail lamp is from VW Golf(Rabbit) MK1

It’s not a direct fit. It needs a skilled sheet metal worker.
Few more pics of it’s development are in the starting of my Thread.

One more pic with all the fittings completed. This Pic angle is my favorite.
1) The Air Scoop viewed from the rear. 2)The Back Wiper & Tail lamp are not a part of Van‘s OE. 3) Rear camera between the two number plate lights .
Image may have been reduced in size. Click image to view fullscreen.


Alternative mechanical Brake switch……...64 LED clustered Third brake light……..........Brake lights are lit when brake applied
Image may have been reduced in size. Click image to view fullscreen.
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narendra.vw
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PostPosted: Tue Jun 30, 2015 5:48 am    Post subject: Reply with quote

Cable shifter update,
I’m not confident with the cable I got & no feedback yet to give me confidence to go ahead. In fact the cable shifter fitting are still on the gearbox.
Shifter unit placement(note, the OE shifter rod is still in place).
Image may have been reduced in size. Click image to view fullscreen.

Arrow indicates a hole needed for the shifter rod space inside the cabin.

Cup holder at it’s rightful place.
Image may have been reduced in size. Click image to view fullscreen.


In the mean time. Some brain teaser!!

The picture bellow shows a exploded view of a unit. Once the parts are reassembled together & fitted, the parts as a Unit turn into a handy Tool of comfort for the Van user.
I call this ‘Mother of all my Mod‘.
Just to make things more interesting, I wish you to solve the Puzzle by guessing the Tool.

Hint:-
--A universal Tool for all VW van models .
--The Unit fitment is inside the van but it has nothing to do with the Interiors.
-- The Mod will boost of being in ‘Present generation‘.

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

The unit has been tried & tested. It worked beyond my expectation.

Good lock.
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Gnarlodious Premium Member
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PostPosted: Tue Jun 30, 2015 9:31 am    Post subject: Reply with quote

Electric sliding door latch?
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Zeitgeist 13
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PostPosted: Tue Jun 30, 2015 9:56 am    Post subject: Reply with quote

That's what I was thinking
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narendra.vw
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PostPosted: Wed Jul 01, 2015 6:17 am    Post subject: Reply with quote

Hi, Gnarlodious,
The power latch opening was done way long back. At a press of a switch the slider door latch unlocks.
Thanks for the reply.

Hi, Zeitgeist 13,
Thanking your reply I like to wait for few more.
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Brandonfast
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PostPosted: Wed Jul 01, 2015 6:23 am    Post subject: Reply with quote

Automatic hatch operation?
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newfisher
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PostPosted: Wed Jul 01, 2015 6:42 am    Post subject: Reply with quote

Auto sunroof?
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