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7 seater Caravelle Syncro to camper
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vik
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PostPosted: Sun May 13, 2018 3:36 am    Post subject: 7 seater Caravelle Syncro to camper Reply with quote

Hi guys,

I would like to introduce our bus here. We purchased the car last year in autumn but than we were moving and had not so much time to work on the car. Later we decided that based on our working schedules a specialist would be better solution Sad
Meanwhile I sourced number of items needed/wanted for the conversion.

The bus in 7 seater Caravelle Syncro with 2.1 and we are changing it to a camper. It has around 300.000km on the clock. Previous owner made some body repairs so it was solid, but we found 2-3 spots which required attention.
This is how it started:
Image may have been reduced in size. Click image to view fullscreen.

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

In Germany I found a Westfalia Mozaik roof kit. It needed respray and new tent with a seals, but other than that it was in good condition. In the roof there is a 100W solar panel connected to CTEK charger/regulator to keep thinks simple.
Image may have been reduced in size. Click image to view fullscreen.

Full interior was insulated and rear heater delete was performed as the RnR bed from M1 campers has inbuilt seat belts, but it is not as big as westy bed.
Image may have been reduced in size. Click image to view fullscreen.

I sourced refurbished propane heater from Trumatic to help us in chilly conditions.
Plywood was used for cabinets and walnut for top.
Image may have been reduced in size. Click image to view fullscreen.

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

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

On front we removed the bars as I can not get trough government tech checks with it and install LED bar (180W I think) to help at night.
Image may have been reduced in size. Click image to view fullscreen.

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


Now remains the EJ25 conversion and hopefully by Sep (this year) we will be on the road to Spain.
Image may have been reduced in size. Click image to view fullscreen.


Waste water is Westfalia. Fresh water is plastic custom made to fit between the beams under moving doors. And we found an propane tank similar to original which can fit under floor as well. But lead time is like 6 weeks Rolling Eyes
AND still missing interior lighting...

It is not ¨westy¨ but I hope you like it.
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Team WorldTour Premium Member
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PostPosted: Sun May 13, 2018 3:55 am    Post subject: Re: 7 seater carawelle syncro to camper Reply with quote

Greetings from Germany!
I'm not sure what you have for 'Baumarkt' in Poland, but if you have OBI, I would recommend THESE. You can cut and reconnect them (or link multiple strings together) and run them everywhere.
Image may have been reduced in size. Click image to view fullscreen.


The beauty of the LED is that it runs on 5v DC. Wire it right into the van with no issues!
That massive wall plug has a transformer in it to change the Input voltage from (whatever)v AC to 5v DC. Also, a string will provide enough light (and color!) to your evenings without draining the battery!
(Just last month, the Missus and I were out camping for two weeks, fridge on gas, and no shore power. Ran the van 15 minutes every two days, and the House Battery didn't even notice they were there....)
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vik
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PostPosted: Sun May 13, 2018 4:38 am    Post subject: Re: 7 seater carawelle syncro to camper Reply with quote

Team WorldTour wrote:
Greetings from Germany!
I'm not sure what you have for 'Baumarkt' in Poland, but if you have OBI, I would recommend THESE. You can cut and reconnect them (or link multiple strings together) and run them everywhere.
Image may have been reduced in size. Click image to view fullscreen.


The beauty of the LED is that it runs on 5v DC. Wire it right into the van with no issues!
That massive wall plug has a transformer in it to change the Input voltage from (whatever)v AC to 5v DC. Also, a string will provide enough light (and color!) to your evenings without draining the battery!
(Just last month, the Missus and I were out camping for two weeks, fridge on gas, and no shore power. Ran the van 15 minutes every two days, and the House Battery didn't even notice they were there....)


Hi

Yes there are Baumarkts in Poland Smile
BUT I'm Czech, bought the car in Poland, but now living in Ireland to keep it simple...
I still have the Polish license plates as I want to register the car in Germany trough a shop who helped me with the conversion as it is not legally possible to mount different engine in a car in CZ...

I'm more thinking about these:
https://www.conrad.de/de/led-innenraumleuchte-12-v...30132.html
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vik
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PostPosted: Thu May 21, 2020 5:48 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Small update on my long term project

- Finally have technical approval (TÜV) so can register the car with EJ25
- EJ25 had a knock so the engine had to be rebuild
- I managed to get CLKs and they are powder coated now. I have chosen Nokian Rotiiva A/T 215/70 R16
- Big front brakes are installed too

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

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


To do list (not complete)
- finish interior build
- install water and gas tanks
- get new lightbar
- sort out temperature reading
- get the rear locker light working (this can lead to gearbox out situation)
- BMW booster install
- some rust
- and, and, and Smile
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PostPosted: Thu May 21, 2020 9:18 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Looking good. Hope you get on the road finished soon.
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vik
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PostPosted: Thu Jun 25, 2020 5:14 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

During the ending quarantine there was not so much options to do so based on the weather I was working on addressing some issues, especially the shifting.
Before:
Image may have been reduced in size. Click image to view fullscreen.

After I change all bushings shifter cup and ball + painted rods and rebuild the shifter as well
Image may have been reduced in size. Click image to view fullscreen.

Much more smoother now.

When I was at it the windshield washers stop working. After going trough WHOLE system and wiring I found to have faulty relay Laughing
At least I cleaned everything
Image may have been reduced in size. Click image to view fullscreen.


Easy stuff was painting the gas filler housing. Primer for plastic and black paint in the spray can made large difference. Looks almost like new.
Image may have been reduced in size. Click image to view fullscreen.


Pop top got attention too: cleaning, rust removal and painting
Image may have been reduced in size. Click image to view fullscreen.

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


btw: anyone have an idea where to get this plaque? I do not have it on the car anymore.
Image may have been reduced in size. Click image to view fullscreen.

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PostPosted: Mon Jun 29, 2020 9:56 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Small update here
New radiator ducts installed meeting up with SA radiator from Brickwerks.
Image may have been reduced in size. Click image to view fullscreen.


But much more interesting item has been delivered from Germany today - ADH front diff (with locker). Price was really good - seller had wrong description on the item. Taking in consideration that locker alone is €800... Only I have to wait till end of the month to have it installed as local specialist has vacation. AND my bus has 6N which means different final drive so they will have to take final drive from my old one to the ¨new¨ one + few bits and bobs.
Image may have been reduced in size. Click image to view fullscreen.

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PostPosted: Fri Jul 17, 2020 2:01 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Hi I might need some help here...

My bus seems to run tad hot based on the gauge.
- I installed new radiator baffles
- Soldered new 28Ohm resistor
- founded out that PO made interesting wiring nest in place of the foil + strange wire is hooked to the yellor/red wire for the temperature gauge (need to investigate that further).
- I do run Burley cooling pipes and non reversed manifold
- My engine is EJ253 which has different water pump:
Image may have been reduced in size. Click image to view fullscreen.

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

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

- I can not see any bypass for heater installed
Diagram how the cooling system is in place:
Image may have been reduced in size. Click image to view fullscreen.

Comparing with Burley one
Image may have been reduced in size. Click image to view fullscreen.

seems to me that lower exit of the expansion tank shall meet with return from the heater and merge before the Subaru bypass tube and not to be connected to the "hot" side of the heater circuit.
Shall it modified like this:
Image may have been reduced in size. Click image to view fullscreen.

Or am I wrong?

Thank you
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zoti
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PostPosted: Sat Aug 08, 2020 10:32 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Who did your cabinets?


vik wrote:
Hi guys,

I would like to introduce our bus here. We purchased the car last year in autumn but than we were moving and had not so much time to work on the car. Later we decided that based on our working schedules a specialist would be better solution Sad
Meanwhile I sourced number of items needed/wanted for the conversion.

The bus in 7 seater Caravelle Syncro with 2.1 and we are changing it to a camper. It has around 300.000km on the clock. Previous owner made some body repairs so it was solid, but we found 2-3 spots which required attention.
This is how it started:
Image may have been reduced in size. Click image to view fullscreen.

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

In Germany I found a Westfalia Mozaik roof kit. It needed respray and new tent with a seals, but other than that it was in good condition. In the roof there is a 100W solar panel connected to CTEK charger/regulator to keep thinks simple.
Image may have been reduced in size. Click image to view fullscreen.

Full interior was insulated and rear heater delete was performed as the RnR bed from M1 campers has inbuilt seat belts, but it is not as big as westy bed.
Image may have been reduced in size. Click image to view fullscreen.

I sourced refurbished propane heater from Trumatic to help us in chilly conditions.
Plywood was used for cabinets and walnut for top.
Image may have been reduced in size. Click image to view fullscreen.

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

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

On front we removed the bars as I can not get trough government tech checks with it and install LED bar (180W I think) to help at night.
Image may have been reduced in size. Click image to view fullscreen.

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


Now remains the EJ25 conversion and hopefully by Sep (this year) we will be on the road to Spain.
Image may have been reduced in size. Click image to view fullscreen.


Waste water is Westfalia. Fresh water is plastic custom made to fit between the beams under moving doors. And we found an propane tank similar to original which can fit under floor as well. But lead time is like 6 weeks Rolling Eyes
AND still missing interior lighting...

It is not ¨westy¨ but I hope you like it.
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vik
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PostPosted: Sun Aug 09, 2020 11:04 pm    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Hi Zoti,

They are custom made by this company: http://vejnywood.cz/
It is one of their earlier jobs, so I find it rough around edges here and there. Roughly Oct. I will install original Westy bed in the back thus have to cut few cm off the units Crying or Very sad
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PostPosted: Mon Aug 10, 2020 5:42 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

vik wrote:
Hi Zoti,

They are custom made by this company: http://vejnywood.cz/
It is one of their earlier jobs, so I find it rough around edges here and there. Roughly Oct. I will install original Westy bed in the back thus have to cut few cm off the units Crying or Very sad


Thank you. It was fun to look through their gallery and see what interiors they have done.
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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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PostPosted: Mon Aug 10, 2020 7:23 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

vik wrote:
Hi Zoti,

They are custom made by this company: http://vejnywood.cz/
It is one of their earlier jobs, so I find it rough around edges here and there. Roughly Oct. I will install original Westy bed in the back thus have to cut few cm off the units Crying or Very sad

Their ideas for the cabinetry are fantastic! I love the pull-out rear kitchens - and the wine and wine glass storage cabinet!!!
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vik
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PostPosted: Mon Aug 10, 2020 11:52 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

You're welcomed.
I have to admit when I have seen their latest work - they moved forward by a long stretch.

At the same time - I was looking for Westy interior, but it was simply not possible to find one at the time of search (it is not much better these days).
I think that in Europe you can find much more custom jobs (along with the original Reimo, Carthago and some others).

So
T -9 days before we will try to go for the vacation south
- borders are so far ope
- today I got bunch of parts to replace blower motor, switch (it fried last week) as well as the resistor and heating matrix. I think that resistor is last to come the day after tomorrow.
- install new stereo
- repair skylight
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PostPosted: Thu Aug 13, 2020 10:38 pm    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Due day is approaching faster than I would like. But there are some things done already.
- skylight is fixed
- radio is working again (and new one is wired)
- speakers replaced. The new once shall sound much better and won't fall off the door cards.
- Instrument cluster repaired. I printed out new edges to fit the new cut outs and glued everything together with mix of epoxy and microbaloons. So far it looks ok. Not the best job though. Thank you Samba -> I found inspiration in one of the older threads here.
Image may have been reduced in size. Click image to view fullscreen.

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Heater core is ready to be taken out and lets hope I will start to put it back together on Sat. The BMW brake booster will probably stay in a box this time. As much as I would like to have it installed some safety margin on time is better for me at the moment.
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PostPosted: Fri Sep 11, 2020 3:01 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Last 3 weeks we spend on a big shakedown in a bus covering about 3500km to Corsica (trough Austria and Italy). I tried to finish everything on time, but basically had no option to test it which resulted in tow truck assistance, and new wheel bearing as bonus most probably due to not really good work of a mechanic (he hammered back stub axle). List of to do thinks is now longer than before Rolling Eyes
Image may have been reduced in size. Click image to view fullscreen.


To the good stuff.
We took a ferry Livorno-Bastia and started round trip around the island in the counter clockwise direction. Vanagon size is good to tackle roads there but first day I was not using 4th gear at all. Later I found that part of the route we took is actually part of Tour de Corse WRC.
Image may have been reduced in size. Click image to view fullscreen.

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We tried to mix the trip of coastal areas as well as beautiful mountains. Benefit there was decent number of small streams or rivers where you can swim and we took this option whenever we could.
Image may have been reduced in size. Click image to view fullscreen.

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Mostly we tried to stay in nature and avoid campsites (although not always it was possible and some of the camp sites were horrible, honestly). Worst case police or park rangers came and told us to move along.

As we progress south from the beach perspective was south east coast the best and our son really enjoyed it.
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On way home we had short stops in Pisa and Lago di Garda before going over the alps.

We do have many memories on these 3 weeks. On Corsica we met people who were 100% positive or people who were on the opposite of the scale. Not speaking French did not help either and it was not uncommon to ask a question in English and receive answer in French. But I guess that is part of the experience Laughing
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PostPosted: Fri Sep 11, 2020 5:53 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

That is quite a shakedown! The mountains are so beautiful over there. I can't imagine going up them. I struggle with the semi-trucks in the right lane going over 700m mountains at 70kph, I can't imagine trying to go over anything bigger.

Are you considering a motor swap now? Laughing
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PostPosted: Fri Sep 11, 2020 6:52 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Wow, nice job with the restoration and it looks like a great maiden voyage. Thanks for sharing!
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PostPosted: Fri Sep 11, 2020 8:04 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Thank you,

I do have EJ253 so maybe longer 3th and 4th gear will be better. But have no problem go 110km/h over the Alps.
And this winter the engine will need to be rebuild due to extensive oil consumption and sometimes blue smoke Sad

And yes, the restoration - would it ever end?
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PostPosted: Wed Nov 04, 2020 10:39 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Just a quick update.
A cylinder compression test has been completed with a clear result.
3 cylinders are top notch
1 cylinder is super close to be considered out of tolerance
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If I found it correct top shall be 185PSI and lowest shall be 148PSI

This explains high oil consumption Rolling Eyes
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PostPosted: Wed Nov 04, 2020 10:53 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Vik, do you have any more information about the rear bench (manufacturer, how to obtain it, how it was installed) ?

It has the integrated shoulder belts attached to the bench, which will eliminate the need of cutting a slot on the rear cabinet (which the GW instructions ask you to do to use their kit with the rear mounting points).




vik wrote:
Hi guys,

I sourced refurbished propane heater from Trumatic to help us in chilly conditions.
Plywood was used for cabinets and walnut for top.
Image may have been reduced in size. Click image to view fullscreen.

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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