Battle Jitney Syncro camper build thread

[rmcd]

[rmcd]

I converted my tin top to a panel van using OEM transplant parts. Now I need to create panel walls for the inside. I've already got a set of Werksberg panels for the front doors and lower half of the slider door. Eventually I'll be upholstering them. For now I'll run plain black. JM has grey now too.

Some before and after photos as a refresher.

After.

I was lucky enough to find a NOS panel van door. I'm using a Werksberg for the bottom but need to make a template to cover the top.

And need to cover this up. I will drill some holes for the vents to function.

I used the old OEM panels as part of the template. I've added paper to extend the template. Unfortunately, the ABS plastic comes in 48" widths and to do these panels in a single piece requires 51". So I'll be splitting this template down the middle.

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VW LT40 build. Like a Vanagon but 30% larger in every direction and 40% slower even in metric.
https://www.thesamba.com/vw/forum/viewtopic.php?t=749359&highlight=

[rmcd]

I'm retrofitting an OEM jumper seat into the van. My intent is to use these brackets to hold the jumper seat, but also to use them to hold other items in place. Maybe a porta-potty or cooler or ....?

Added sections of pipe to the floor.

Welded nuts to the pedestal. And I think I went as far as a backer plate in the wheel well. I covered with seam sealer and can't really remember.

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VW LT40 build. Like a Vanagon but 30% larger in every direction and 40% slower even in metric.
https://www.thesamba.com/vw/forum/viewtopic.php?t=749359&highlight=

[sanchius]

[rmcd]

Sorry to say but I don't remember who I got them from German EBay. Scotty too long ago.

Not there is room to put a swing away tire carrier brace?

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VW LT40 build. Like a Vanagon but 30% larger in every direction and 40% slower even in metric.
https://www.thesamba.com/vw/forum/viewtopic.php?t=749359&highlight=

[rmcd]

Screwing around so I repurposed some aeronautical lights to replace the red plastic side light.

I put in a side and rear LED Task lights. I used plugs so I can swap out.

Added some bars to the headlights from a 7" jeep light. E-code 7" h4 with vwguys ceramic connectors and relay kit.

R&R all the light fixtures.

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VW LT40 build. Like a Vanagon but 30% larger in every direction and 40% slower even in metric.
https://www.thesamba.com/vw/forum/viewtopic.php?t=749359&highlight=

[86scotty]

Amazing build!

And hilarious. I throroughly enjoyed reading it........all..........today. Somehow I missed it before.

Did I miss what you used for bedliner on the lower section? Raptor? Rhino? Something else? Sprayed or rolled? I like the look of the texture.

Thanks
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86 Vanagon Westfalia 87k
1998 Ford E350 4x4 camper build
Vans flip flops

[rmcd]

Thanks. My painter applies the black bedliner. Not sure the brand sorry.
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VW LT40 build. Like a Vanagon but 30% larger in every direction and 40% slower even in metric.
https://www.thesamba.com/vw/forum/viewtopic.php?t=749359&highlight=

[rmcd]

More work on the power accessories.

Installed the Thermo regulator relay, power accessory dash harnesses out of a donor carat, and the proper OEM fuse block.

Fished the door harnesses into the door and dash for the first final time. I sure wish I would have hacked larger holes in the pre-86 doors. In the end it worked. I only bled a little but have to admit I may have cried a bit too.

I still need to cut a hole in the pre-86 door for the power mirror control. Not sure how I forgot that!

Only a few left over wires for what I think are the power locks. Guess we will see on the next episode. Same bat time. Same bat channel.

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VW LT40 build. Like a Vanagon but 30% larger in every direction and 40% slower even in metric.
https://www.thesamba.com/vw/forum/viewtopic.php?t=749359&highlight=

[dkoesyncro]

Looking good Ron, keep up the progress.

[rmcd]

Finishing up the power windows and mirrors. I have all the power lock parts and All the provisions are there for locks but I'm not going to do them at this time.

Now I'm trying to figure out the crazy mirror clutches. Mirrors only go up on driver side. Housings rebuilt, new glass, and new gaskets.

Gowesty has a nice mirror write up. FYI.

http://www.gowesty.com/tech-article-details.php?id=76

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VW LT40 build. Like a Vanagon but 30% larger in every direction and 40% slower even in metric.
https://www.thesamba.com/vw/forum/viewtopic.php?t=749359&highlight=

[rmcd]

Back to the lights.
Had issues with the reverse light switch on the transmission. Replaced it, some bulbs I broke to make an example for the other electronics and all rear lights work.

I added a LED third brake light from a 90's Nissan Pathfinder. They have a ton of aftermarket replacement LED units for it. It also has a provision for a sprayer but you would have to drill out the hole for the washer tube to fit two lines and I had already painted the door. Yea I know!? There are limits to what I will cut into? I surprised myself.

Here is the final side marker light with a red LED bulb. Like it or hate it. Anything is better than the OEM plastic scabs.

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VW LT40 build. Like a Vanagon but 30% larger in every direction and 40% slower even in metric.
https://www.thesamba.com/vw/forum/viewtopic.php?t=749359&highlight=

[rmcd]

Prior to paint I installed rivnuts to support exterior accessory rails. Kayak rack, jack, mats, children booster seats? I put 1/16" rubber gaskets behind these and the scab lights mentioned earlier. More on these rails later.

_________________
VW LT40 build. Like a Vanagon but 30% larger in every direction and 40% slower even in metric.
https://www.thesamba.com/vw/forum/viewtopic.php?t=749359&highlight=

[rmcd]

I like the look of the Carat bumpers. I found this set on CL for cheap as they were broken up. I used Lord Fusor two part epoxy glue and rebuilt them. Great stuff but know that it shrinks over time so MAY not make the best filler. So far so good.

I had to build in some support for the front bumpers, as well as some channels under the bumper to use as mounting points. I also tack weld in channels on top of the bumper as shown. There are some future hidden brackets for some kind of aluminum bumperettes that I will fabricate.

And these are OEM bumperettes in case anyone is curious. I will be doing something a little more utilitarian. But you get the idea.

At some point I found parts of a nackered up OEM chin spoiler that I cleaned up a little and painted. These were pretty easy installs. The OEM mounting holes already existed on the fron portion of the bumper. I added the three holes on each footwell area. I used some M6 rivnut inserts and a trip to the hardware store provided the SS mounting hardware. I used a heat gun to straighten some of the intra spoiler connections. Lines up pretty well. Hope it will hold up to a snow bank or two?

Tomorrow I will tackle the rear bumper. It kind of scares me a little!
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VW LT40 build. Like a Vanagon but 30% larger in every direction and 40% slower even in metric.
https://www.thesamba.com/vw/forum/viewtopic.php?t=749359&highlight=

[ALIKA T3]

Man does this van look clean

I love the rails, I thought of doing something similar, but drilling holes makes my heart ache
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Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget

[rmcd]

[rmcd]

Saga of fiberglass cladding continues.

I modified the OEM rear bumper mounts with too much extra steel plate as described in earlier posts. All I reall remember is a hot welding ember melting through my sneakers into the webbing between my toes.

Here is the reinforced bumper.

The fiberglass was munched so I rebuilt it with epoxy glue that is hard like concrete. All painted up.

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VW LT40 build. Like a Vanagon but 30% larger in every direction and 40% slower even in metric.
https://www.thesamba.com/vw/forum/viewtopic.php?t=749359&highlight=

[IdahoDoug]

I cannot wait to see this beast in person. Seriously. If I know we are at the same event, will bring my coveralls just so that I can crawl all over under it to see all the stuff you're doing. Fantasimo!!!

Doug
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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

[rmcd]

Thx. A buddy is going to help with the windshield then it's off to DoubleJ Motorwerks to final the small car AC connections and maybe strive the front diff. At that point it will be a driver again. Fingers crossed.
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VW LT40 build. Like a Vanagon but 30% larger in every direction and 40% slower even in metric.
https://www.thesamba.com/vw/forum/viewtopic.php?t=749359&highlight=

[rmcd]

Finished the carat door cladding.

Bentley OEM measurements are off. I hate how the front door cladding typically does not follow the door body line that is 1/2" away. I was determined to measure correctly and not have mine tilt. I'm here to say OEM Bentley measurements are wrong. I had to redrill the carat mounting pieces to have the front part match the body line. That sucked.

Now I need to adjust the front and rear bumper returns so they alight with the same body line and aren't sloped down. Not sure I can fix the rear.

I like the look of the front spoiler with the cladding.

Also bled the new rad and smallcar AC system. Used a Libby bong. FINALLY got hot coolant to flow to the new AC system. Took a few rounds.

Fan and switches all worked fine. Not sure about trinary switch or rad fan. Need to test that a bit more. New compressor isn't inline yet. Maybe in a few weeks?

Pardon the tape. Its there to prevent garage rash when I inadvertently drag parts, me or dead bodies by the van.

_________________
VW LT40 build. Like a Vanagon but 30% larger in every direction and 40% slower even in metric.
https://www.thesamba.com/vw/forum/viewtopic.php?t=749359&highlight=