Left for Dead...The Resurrection Story....(AWD EE-20)

[Abscate]

Im an old guy with all my fingers, toes, eyes, and no stitches - about 15 years ago I started buying redundant safety equipment and keeping it with the power tools.

Yesterday I was grinding off four BMW exhaust manifold bolts and put a nice scatch on my facemask when the grinder ejected a bolt head off. I was pissed at scratching it right on my sightline....
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.ssS!

[0cean]

Next came the bumper cover. I have to admit that I made this harder then it needed to be, yet it turned out ok.

Bumper upside down in the picture.

They say you shouldn't cut corners when you work, yet I'm ok with it this time

In the end I added about 70 pounds of bumper weight to the van. Its a lot, yet its also a lot of protection for the rear. Moving forward I will see if I can reduce some of the interior weight to make up for the bumper. Its do-able.
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I'm not a mechanic, I just play one on the internet

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)

[0cean]

Should be good light for backing up.

Added place for D rings/ crumple zone. Screw in points for the bumper cover also.

little more shaping

_________________
I'm not a mechanic, I just play one on the internet

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)

[0cean]

Next comes the bumper and sub frame. All I wanted was to be able to tow and have good backup lights.

This will insert into the frame rails and bolt on the inside of the engine compartment.

My welding skills are coming along.. kind of proud of this one.

Housing for the light. Kind of also works as a crush zone in case of impact.

_________________
I'm not a mechanic, I just play one on the internet

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)

[0cean]

[0cean]

You may be right. Its the grinder on the ground in the picture and I would check, but don't have it anymore. The grinders trigger design was really nice and big and that was the whole reason I bought it. O-well, Lesson learned the hard way.
_________________
I'm not a mechanic, I just play one on the internet

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)

[jberger]

[blackglasspirate]

Looking good, Jason. Keep up the good work!

Can't wait to see this beast on the road.
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'87 Vanagon GL Westfalia
IG: @holidayatsee
FB: https://www.facebook.com/holidayatsee

[0cean]

Here you can see the design of the attachment points. It worked out well. Warning: Blood is below like promised.

So wail cutting off the solid bar sticking out the end, The grinder with a large cut off wheel kicked out of my hands and on to my knuckle causing a good 9 hour emergency room night.

All sewn up and ready to go back to work. Later I looked at the grinder and discovered what more then likely happened is the grinders gears stripped and that caused the quick binding and release. The grinder was trashed and I will never buy a Milwaukee grinder again. If they would have used steel gears and not plastic sh@t, then I would not have cut into the joint of my hand.

I added some tubing to the rock slider on the sliding door side for LED lights. I hate not seeing where I'm steeping in the dark. Especially if has rained..

The angle of the Lights. I only did two because I didn't want to disturb the middle of the sliders strength.

Now they are in the pile of stuff going to the powder coater.
_________________
I'm not a mechanic, I just play one on the internet

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)

[0cean]

I don't really understand why I'm building rock sliders for a road and sand surf van, but I thought it was a good idea. Yeah, I don't know why. Anyways

Had to cut out the jack points for a new size.

Parts being used.

Drilled and tapped the tube and solid shaft that will mount the rock sliders.

Here is the rough placement.

So the solid shaft will be the mount for the rock sliders. Welded in the rock slider portion.
_________________
I'm not a mechanic, I just play one on the internet

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)

[xoo00oox]

[0cean]

[xoo00oox]

Looking nice! I'm looking forward to seeing what you do with the winch. Is that shifter cables I see under the van too?? I'm looking forward to seeing more of that too.

[0cean]

Little more bumper building. I added Shackle mounts and a place for the winch cable to pass through the bumper. Little bit later I will start another thread about the bumper winch build because there is nothing out there about it besides Syncro Gregs build, yet this is a little different approach.

About the Shackle mounts. The bumpers are curved and the mounts will not face directly forward and have more angle the further out you go from center. After welding them on, I realized that's going to be a problem with my bumper, who is accully no more then a cover. So now the holes for the shackles in the bumper cover, needed to be bigger then the width of the shackle by a sizable amount due to the angle of the shackle. (Like trying to put a block in a square hole a little side ways. It wont work without opening the square hole) Later I will just add a removable cover to it some how, but I wish I would have done it a little differently from the start.

I did a little trimming of the bottom lip of the crush zone of the vans bumper. Nothing crazy and did take into account for the way it would crumple and did the best I could. Its only the little off the corners anyways.

I did cut off the corners of the bumper because I'm not a big fan of sharp corners on bumpers. Knowing me I would hit someone's car pulling out of parking place and really tear up there little plastic bumpers with my manly bumper forged from steel. Wouldn't want that to happen.

_________________
I'm not a mechanic, I just play one on the internet

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)

[0cean]

Ok, I'm not ready to talk about the rest of the inside mods yet, so lets move on to the front bumper... I wanted to add lighting, yet because I'm in a costal area I also need a good fog light also.. An Ebay search come up with a duel white/amber light that would do both colors from one light fixture. Sweeeeet...

Started the weld in housing for the lights.

Bolts are tack welded to stay in place.

Plenty of room for adjusting angles.

Built in the bumper just like the jeeps.
_________________
I'm not a mechanic, I just play one on the internet

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)

[0cean]

[xoo00oox]

I gues you may as well have a drink if you've got no shifter.


What's your plan for that? I like your work.

[0cean]

Some of you may be wondering why I would extend the hump? Well my friends, for the most important part of the van. The cup holders!!! Yes people, couple holders are a thing of beauty or a thing of be-trail if not located in the right place. But not just any cup holder will do, O-No, only a cup holder that will handle small cans, and coffee cups, and coffee cups with the dreaded handle, and even the mighty Gatorade bottle will need its place!!! (I need to stop watching Dead Wood).

So after the long intronet search I found the proper cup holder for such a task.

Cup holders are ergonomically correct and custom to the Drivers and Passengers positions.
_________________
I'm not a mechanic, I just play one on the internet

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)

[0cean]

[vanagonjr]

What are you doing for the gas tank? Inquiring minds want to know!
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John - 86 Wolfsburg Westfalia "Weekender"
Flint reversed 1.8T W/Passat 5-Speed
LiMBO (late model bus club) www.limbobus.org
LiMBO is on Facebook too! https://www.facebook.com/groups/
FAQ thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=525798