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Battle Jitney Syncro camper build thread
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rmcd
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PostPosted: Mon Jan 18, 2021 10:59 am    Post subject: Re: Battle Jitney Syncro camper build thread Reply with quote

Phishman068 wrote:
I had no idea the iota charger would fit in the shallow portion under the seat!
Are your seats on risers or something, or does the iota charger really fit there on a stock setup?


Shoot. Forgot. I put in rails. It is raised.

Third post edit. Coffee not effective today. Looking at it. Definitely maybe. I’ll post a new picture in a few.

It took some thinking. I gain a ton of space once I was resolved to a second level of ply base material.

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rmcd
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PostPosted: Mon Jan 18, 2021 11:09 am    Post subject: Re: Battle Jitney Syncro camper build thread Reply with quote

Iota is below the rail.

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erste
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PostPosted: Mon Jan 18, 2021 11:56 am    Post subject: Re: Battle Jitney Syncro camper build thread Reply with quote

rmcd,
Hope you don't mind me reposting these two pics:
rmcd wrote:
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Fantastic work bringing new life to those cabinets!
Thanks for sharing the details on the laminate and the shelf liner.

Nice updates!
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rmcd
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PostPosted: Mon Jan 18, 2021 10:17 pm    Post subject: Re: Battle Jitney Syncro camper build thread Reply with quote

Thanks for the nice comments. Labor of love as they say. And I learned how to do laminate!
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VW LT40 build. Like a Vanagon but 30% larger in every direction and 40% slower even in metric.
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rmcd
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PostPosted: Wed Jan 27, 2021 11:23 pm    Post subject: Re: Battle Jitney Syncro camper build thread Reply with quote

I did a couple iterations of this.

Started with an off the shelf hi-jack truck bed mounting bracket kit and big bolts. I hate that I had to use the lower part to mount the tracks.

I had been reserving the lower part for a snowboard rack!

I like these tracks because they also had a jack stand base built into the pattern. And they were blue?!


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VW LT40 build. Like a Vanagon but 30% larger in every direction and 40% slower even in metric.
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rmcd
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PostPosted: Sat Jan 30, 2021 11:51 pm    Post subject: Re: Battle Jitney Syncro camper build thread Reply with quote

Kind of final pictures of the westy interior swap, the eu sourced black out window shades, my sewfine cab curtain, dash work, and the overhead switch and gauge console.

I still need some trim and a piece of table hardware. And the seat cushions are being re upholstered to match the front seats.

Side window curtain.

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Rear window. This is two kits to fit one window given the size of the glass. Well one and a half.

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Cab blackout curtain.
I added snaps at the wall. It came from Sewfine with snaps to hold them together. I had to modify the sewfine kit. I added my own curtain rod and a larger spacer to accommodate the bunched up material. And I added the white blackout material.

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The latest overhead console and dash work. I used airplane post lights to provide some illumination for the switches and stuff.

I used Ram mount holders with their l track like rail. Lots and lots of options.

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Westy cabs.
I hollowed out the water tank so it is all storage and the occasional diesel heater duct.


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I’ll do a build summary next.
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erste
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PostPosted: Sun Jan 31, 2021 12:14 am    Post subject: Re: Battle Jitney Syncro camper build thread Reply with quote

So nice!!
I like those blackout curtains. Haven’t seen that style before.
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rmcd
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PostPosted: Sun Jan 31, 2021 9:28 pm    Post subject: Re: Battle Jitney Syncro camper build thread Reply with quote

erste wrote:
So nice!!
I like those blackout curtains. Haven’t seen that style before.


Thanks. I got them here.

https://van-x.co.uk/?s=t3+curtain&post_type=product
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PostPosted: Sun Jan 31, 2021 10:32 pm    Post subject: Re: Battle Jitney Syncro camper build thread Reply with quote

So the curtains come with the upper and lower rods?
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rmcd
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PostPosted: Mon Feb 01, 2021 12:12 am    Post subject: Re: Battle Jitney Syncro camper build thread Reply with quote

tjet wrote:
So the curtains come with the upper and lower rods?


Yes. Powder coated aluminum tracks that accept the plastic tabs that are sewn into the curtain material. Also includes small plastic end caps.

Keep in mind there was not Vanagon kit. I had to order two kits for the rear window and only use some of the materials.

Good news. I have enough left over supplies to do the window on the VWLT!
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PostPosted: Mon Feb 01, 2021 12:26 am    Post subject: Re: Battle Jitney Syncro camper build thread Reply with quote

That thing will be awesome. I want one now.
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rmcd
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PostPosted: Thu Feb 04, 2021 4:22 pm    Post subject: Re: Battle Jitney Syncro camper build thread Reply with quote

Here is an end of build summary that I thought would be fun.
After doing this I'm kind of embarrassed about how many hours I've spent!

I wanted this to be a picture extravaganza. I think I've achieved that! There are a few missing things or outdated pictures but I think you get the idea.

Enjoy. And yes, I will consider serious offers.

All pictures here. https://www.thesamba.com/vw/forum/album_search.php?search_author=rmcd&show_results=summary

External pictures.
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Motor, Transmission and Related Mechanical Work.
1.9 ALH TDI installed at 95,000 miles by Northwesty.
All aluminum Saab Intercooler with puller fan. Intercooler isolated from engine compartment and vented below. Cold air intake via an intake scoop on the exterior vent.
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New VNT17 turbo and manifold in 2019. New injectors and Malone tune at same time.
Custom intake manifold with EGR delete.
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Custom exhaust installed with custom fab aluminum heat shield, hanger bars and skid plate.
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Custom OEM-style diesel mounting bars with new hydraulic mounts.
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New Alternator, AC compressor, and Power steering pump in 2019.

New Donaldson air filter system vented through OEM snorkel.

New Donaldson PCV oil vapor capture system.

OEM cluster modified with TDI tach.

Transmission rebuilt by AA Transmissions.
Gearing upgraded to match TDI and reinforced with retainer plates. Oil tests run on each oil change since trans rebuilt.
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Trans oil test results here.
http://www.thesamba.com/vw/forum/album_search.php?...ts=summary

Custom aluminum skid plate for trans and motor.
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Custom heavy duty drive line and motor skid bars.
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Rare OEM syncro skid plate fitted for front transfer case.
Vented for added cooling.
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Front transfer case rebuilt in 2019.
De-coupler and OEM de-coupler knob added. Solid shaft replaced viscous coupler.
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Syncro tank refurbished. All new hoses including filler hose. New stainless mounting straps.
Fuel level sender just broke.
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Shifting linkage all refurbished in 2020.

New front radiator, radiator fan, wiring and sensors (AC, coolant).
Rad fan redundant ground added.
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New front wiper motor installed.
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Rear OEM hydronic heater and fan refurbished and functioning well.

New stainless steel coolant lines.
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Suspension and Brakes
Northwesty front big brake kit installed at 95,000m. New rear drums and pads fitted. New e-brake cable installed. All rotors and drums turned to match pads.
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CLK 16” aluminum forged rims black powder coated and fitted with VW logo custom center caps and wrapped with Geolander tires.
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Front suspension bushings and connections all replaced in 2018 except radial rod bushes.
New front springs and shocks.
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Rear springs from UK Triple A vans. Extra heavy duty rating.
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Rear Gabriel Hijacker air shocks. Tower and rear carrier all plated for extra reinforcement.
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Rear CV joints replaced 2020.

Body Work, Paint and Modifications.
Panel van conversion. Welded in OEM panel van sheet metal pieces in rear side windows.
OEM NOS panel van slider door fitted.
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Extensive rust repair completed on front, sides and rear of van. Rusty material removed. Full weld replacement metal, seam repair, sealed, primed, single stage paint.
Paint, new seams and body work completed in 2018. Land rover Caledonian Blue.

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All interior and exterior plastics refinished with SEM paint.

Windows professionally tinted all around.

All door and window rubbers and scrapers replaced.

New door handles all rekeyed to match ignition.

Front windows converted to power windows.

Power, heated mirrors R&R and installed. Passenger side motor not working.

Carat custom bumpers installed front and rear. Both reinforced with tube steel.
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ASI Riviera pop top restored and installed.
New canvas, new hardware, insulated, painted inside and out, LED lights installed.
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Custom locking aluminum cover for pop-top luggage area. Wiring and mounting for Tailgater mobile satellite dish. Wiring plugs for solar panel to support removable panel on 30’ extension cord.
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Carat front air dam fitted.
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Carat door side skirts fitted.
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Fabricated custom 2x2x1/4” tow bar mounted to frame rails with custom 3 bolt rails. TIG welded 3/8”plate to hold a motorcycle carrier.
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Solar powered roof fan installed.
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RMW rear spare tire carrier fitted.
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Black anodized aluminum L-Track installed on driver side. Currently accessorized to carry Hi-lift Jack and sand mats.
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Custom fire truck-like fold out ladder steps to gain access to luggage storage.
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Interior work.
QuietCar sound attenuation spray applied to all walls, doors and floors from front clip to engine compartment.
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80 mil sound deadening mat on all surfaces.

Second Skin LuxuryLinerPro MLV/Foam mass load vinyl and foam layered sound insulation added to engine compartment.

Oem cork retained in cab and rear floor area for extra sound and thermal insulation.

Sewfine 27 oz heavy jute floor padding mat used throughout.

2” high temp-rated poly iso rigid insulation in all wall cavities.
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Sewfine seat covers fitted throughout.
Sewfine headliner installed. Custom upholstering of roof opening hardware with matching vinyl.
All interior carpet and wall vinyl replaced with new by Beaverton Auto Upholstery.
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Werksberg plastic door panels throughout.
Custom made panelvan interior plastic panels fitted. Beaverton Auto Upholstery covered.
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Rear shoulder seat belts fitted.
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Under seat locker by RMW.
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Custom install of OEM jumper seat.
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Dash and Overhead console re-covered.
Dash fitted with custom Ram mount rail and accessory holders for phones, tablets, drinks. Dash customized with extra USB charge station and rare OEM-delete for glove box.
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Camper interior setup.
Westy cabinets and z-bed refurbished and installed.
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Westy stove modified to run off 1# bottles.
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New Shurflow faucet and pump wired to work together.
Refer removed and replaced with shelves.
Westy water tank removed and cabinet opened up for extra storage.

OEM grey water tank installed under chassis.
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Reimo German 60L fresh water tank installed under chassis.
New self priming pump, supply, vent and drain lines installed.
New external and locking fill spout installed.
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5KW diesel parking heater installed under chassis.
Encased in SS OEM box and wrapped in an aluminum skid plate for added protection.
Controller upgraded to wifi enabled Afterburner controller.
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Smallcar AC system installed. Wired into OEM AC controllers. Wiring upgraded to handle load.
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Airplane post lights added to Smallcar AC panel and dash.
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TransAwn 2000 refurbished and installed. Case paint is peeling badly.
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Custom Sewfine blackout cab curtain fitted.
Blackout material added. Curtain snaps added to closure and to fasten to walls.
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European blackout curtains fitted to side window and rear hatch.
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Custom rigid Molle panel storage system fitted to rear.
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Lighting, Solar and related electrical upgrades.
50 LED light bar.
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Custom Heckleblende light surrounds.
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Headlights upgraded to round e-code lights. Custom headlight protection bars fitted. New headlight switch and ceramic H4 plugs. Headlight relays and wiring upgraded.
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Custom rear side marker running lights using vintage airplane lights.
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Custom rear 3d brake light fitted from Nissan.
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Trailer hitch plug installed.
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Custom side and rear work LEDs. Toggle switch at dash console.
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Custom rear camera system integrated with OEM-like rear view mirror.
Overhead console wired for coax radio to rear vent.
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15amp 12V cigarette style outlet in Westy cabinets. Since relocated to side of Westy cabinet.
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Custom satellite dish and TV setup fitted. Wiring and mounting for Dish network Tailgater mobile satellite dish on roof with wiring to cabin. Custom aluminum TV mount on swing arm capable of holding 35” TV outside slider door or inside. Dish, controller and TV not included with sale.
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New air horn installed with new relays.

House battery system.
Installed under the seats. Two AGM deep cycle batteries.
90AH AGM houses battery managed by Ctek d250, Ctek solid state MPPT solar controller and Smartpass 120 charging system. Ctek system is a alternator battery charger, solar controller, isolator and combiner for charging and managing both batteries.
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Custom 120W solar panel system. . Tiltable and removable. Room to add another panel.
Plug setup to facilitate moving the panel away from the van.
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Auxiliary fuse panel and high amp circuit breakers.
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Iota30 110V mains charging system.
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Each battery fitted with Anderson-style connections to facilitate high voltage jumper cables, inverters or charging needs. House battery also fitted with a junction box capable of supporting Anderson plugs and USB plugs. Each battery fitted with Victron Energy blue tooth battery monitoring devices.
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OEM cluster R&R. Speedometer rebuilt by Portland Speedometers. Plastics repaired and reinforced. Red LEDs swapped in and tach modified to read TDI RPMs. Coolant warning light not calibrated. Dash re-upholstered.

Custom Overhead Console fitted. Upholstered to match dash. New multi-function MGL Avionics gauges to measure boost, EGT, trans temp, oil temp, oil pressure, coolant temp and more un-used inputs. Custom airplane task light, removable map lights and post lights installed.
Custom toggle switches installed to control 50 light bar, side working lights, intercooler fan and a spare.
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VW LT40 build. Like a Vanagon but 30% larger in every direction and 40% slower even in metric.
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PostPosted: Sat Mar 20, 2021 10:32 am    Post subject: Re: Panel conversion Reply with quote

rmcd wrote:
I've always thought the rear windows in a Vanagon are kind of useless.
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I like this idea of removing the rear windows and using the OEM windowless panels. I wonder if a rear hatch one is available.
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PostPosted: Sat Mar 20, 2021 10:57 am    Post subject: Re: Battle Jitney Syncro camper build thread Reply with quote

Thanks for bumping this. I missed the summary. It's an eleven page time-machine.

Cool.
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Current: 1990 Westy Camper - Bostig RG4, 2wd, manual trans w/Peloquin, NAHT high-top, 280 ah LFP battery, 160 watts solar, Flash Silver, seam rust, bondo, etc., etc.

Past: 1985 Westy Camper - 1.9 wbx, 2wd, manual trans, Merian Brown, (sold after 17 years to Northwesty who converted it to a Syncro).
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PostPosted: Sat Mar 20, 2021 12:36 pm    Post subject: Re: Battle Jitney Syncro camper build thread Reply with quote

Good on you Man! Long effort with the vision to see it all the way to the finish.
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Steve M.
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PostPosted: Sat Mar 20, 2021 12:45 pm    Post subject: Re: Panel conversion Reply with quote

tjet wrote:

I wonder if a rear hatch one is available.

I think it might be easier to replace the glass with a piece of aluminum in the window seal and mount a reverse cam inside for the rear view.

I've got a cam with the mount tab just slide under the rear trim for the headliner fabric. It's working pretty good, but today I'm removing a section of the window tint for a lighter view in the mirror daytime when driving into the sun. I've been driving with a rear curtain closed to see how I like it. So Far 50/50 on the decision.
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tjet Premium Member
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PostPosted: Mon Mar 22, 2021 11:34 am    Post subject: Re: Panel conversion Reply with quote

Steve M. wrote:
tjet wrote:

I wonder if a rear hatch one is available.

I think it might be easier to replace the glass with a piece of aluminum in the window seal and mount a reverse cam inside for the rear view.

I've got a cam with the mount tab just slide under the rear trim for the headliner fabric. It's working pretty good, but today I'm removing a section of the window tint for a lighter view in the mirror daytime when driving into the sun. I've been driving with a rear curtain closed to see how I like it. So Far 50/50 on the decision.


Steve, yeah, I'm also wondering if it will be too dark in the back of the van with the rear hatch glass replaced with metal.

I made this pic below with the idea of adding a smaller rear window installed in a window blank. The smaller window opens, and has a screen

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


This is the window. Part #CRL AW1033

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tjet Premium Member
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PostPosted: Mon Mar 22, 2021 11:40 am    Post subject: Re: Battle Jitney Syncro camper build thread Reply with quote

It's somewhat proportional to a Doka/Sinka rear window

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Steve M.
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PostPosted: Mon Mar 22, 2021 5:07 pm    Post subject: Re: Panel conversion Reply with quote

[quote="tjet"]
Steve M. wrote:


Steve, yeah, I'm also wondering if it will be too dark in the back of the van with the rear hatch glass replaced with metal.


Let me PM you so we do not Hi-Jack this thread! Very Happy
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charleslabri
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PostPosted: Sat Jul 24, 2021 7:27 am    Post subject: Re: Battle Jitney Syncro camper build thread Reply with quote

sweet jebus your build is amazing
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