Well, this is a turn up for the books. Looks like I have a SERIOUS weekend on the van this week as we need two working vehicles on the road. The missus is using my BMW for work as her brother has borrowed her Corsa in Lancaster which means that the ONLY other option is to get the van working. As a result, I have sat back this morning and had a serious think about what I need to get done to make that happen. She does have a valid MoT, so don’t need to worry about that side of things just yet but right now, she isn’t moving. So, how do I make this happen? Looking over the van this morning, I will need to complete the following jobs
1. Paint Bumper
2. Paint Door, window surround and sill
3. Replace brake lines
4. Bleed brakes
5. Fit bumper and number plate
6. Fit Solar cowl
7. Rebuild drivers side door
8. Clean stuff out of the back so it doesn’t fly around
9. Refit new battery
I would also like to get the bonnet protector fitted, although that isn’t a major job and doesn’t affect it being on the road. It would just be nice to protect the fresh paint on the bonnet.
Think I am going to have to get some jobs signed off today to stand a chance, as well as trying to do my day job. Going to be a CRAZY few days, that’s for sure!!
WOW!! All I can say is good luck 😉
OK, managed to get the bumper in paint. Been a bit of a headache though as my hose connector snapped! Euro Car Parts to the rescue (at an high cost) so I was able to get the paint down.
This will cure overnight now and through the morning so once the brakes are done, I can rebuild the front end
Also went out to the van to find a lovely note from one of the neighbours asking if I would like to sell. As much as I appreciate the thought, I’ve waited far too long to get my hands on a T4 I could sort as a project so unfortunately she isn’t for sale. Nice thought though
Looking good, great job on the bumper.
Looking good, great job on the bumper.
Thank you, it was a nuisance to get where I wanted it but I’m glad I perservered
Seriously good morning on her so far, looking more and more likely that I am going to hit my target.
Got the front corner in paint and the bumper installed, Couldn’t find the two 13mm bolts for the bumper but managed to find some perfect replacements band new in my bolt stash
This afternoon I finished the painting I wanted to get done on the passenger side. That’s all of the window surround now painted, as well as half way down the passenger door. I didn’t want to take it any further as I have got repairs I need to get done on the passenger side. While the paint was curing enough to take off the masking, I also got the bonnet protector on. I know that was a bonus job but I found myself floating so thought I would tick something else off….
All in all, really pleased with today’s work. Tomorrow I have the brake lines to do, bleeding the, fitting the new battery and the solar to finish and it’s just a clear out and she should be back on the road
Well, day 2 was an utter disaster. Having done so well on Saturday, I woke with a sense of determination to get this across the line. I have cleared so much off the list, I had every hope that Sunday would be just as successful. How wrong could I be.
Part of the reason it has taken me so long to get the brake lines done on her is that I have been afraid to look under her properly in case I found issues that were going to set the project back. Nothing could have prepared me for what I actually found.
So, picture this…I am down there, laying on the ground looking for a decent jacking point for the rear, carefully looking over the chassis. All is actually looking good but something is bugging me. I can’t put my finger on what but I am convinced what I am looking at just isn’t sitting right. You know that realisation you get when you suddenly realise what you are (or in this case you aren’t) seeing?
There is no exhaust system under there!! Like, nothing!! The cat is there, but from that point back, she is certainly lightweight!!Now, I remember when I heard her running I though she was loud, like there was a hole that could be patched in mild steel, I really didn’t expect to see thin air.
Obviously, that puts the brakes on getting her on the road. And just to make matters worse, I literally just set the jack up to lift the van in to the air and the heaven’s opened on me!! Now, given the discovery that no matter what I did, she wasn’t getting on the road that weekend. I called it. I am not laying on the floor for an hour or two in the pouring rain when it isn’t necessary.
Anyway, managed to get a full stainless exhaust cat back exhaust system ordered which should be here soon, I’ll get the brakes and solar done through the week and hopefully that’ll mean she is back on the road before the MoT runs out on the 16th. Part of the reason I have this rush is I need to take it to Norfolk to a friend of mine to tackle this welding on the back of the van before she is tested. Looks like I am not out of the woods just yet
So, today I have started stripping out the brake lines on the back. I swear everything is welded together back there! It’ll all come out, I know that but it’s certainly fighting me.
The plan was to replace all the hardlines, which are split however I found this on the first flexi I removed….
As a result, I have taken the decision to replace ALL the pipes at the back of the van. I just can’t trust them and the brakes are kinda important.
With the back end up, it’s given me the chance to have a look at the lowering. Spotted the springs are branded VDub Monkey’s Effin Low springs, with a 100mm drop. These look quite new. While I thought that half a job had been done, on further investigation I have found that the van has almost new Sachs HD Super Touring shocks fitted with the relocated top mounts so it HAS actually been done properly and fairly recently.
So, exhaust ordered, new exhaust rubbers ordered and all the rear flexi brake lines ordered so HOPEFULLY it won’t be long before I can rebuild back there. In the mean time, I want to get the rest of the driver’s side brake lines stripped out ready to rebuild.
So yeah, additional problems found but thankfully not expensive ones to sort out.
Just a little update – Things have ground to a halt while I wait for parts….
OK, the good? Exhaust system has arrived, a tasty stainless steel offering with a twin 3″ twin outlets now sat here waiting for the chance to find it’s new home.
The bad? Managed to get the driver’s side brake line off the van but found the flexi sections are badly perished as well. So ordered 4 new sections for the rear, along with a flare spanner to try and get these brass bolts undone. I honestly thing that all of the braking system back there is the stuff it came out of the factory with and as a result, wow, it’s welded together!!
On top of this, the exhaust has thrown up another problem. What it looks like is that the previous owner thought it would be cool to try and make their own side exit exhaust and failed abysmally. Their method? Butcher the pipe just after the catalytic converter. I was struggling to work out why it was impossible to picture how the 4 parts to the new exhaust mounted to the van until I realised that there was about 2 foot of pipe missing!!
So, ordered a fresh cat section for the van as well but this week is turning expensive!!
Loving the progress, at least I get to read something new 🤣
