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1.9 PD Westfalia Atlantic with flipped Passat box

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mazz View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mazz Quote  Post ReplyReply Direct Link To This Post Topic: 1.9 PD Westfalia Atlantic with flipped Passat box
    Posted: 22 Aug 13 at 15:15
After a lot of time and effort we have finished our PD conversion. We used a flipped Passat box on Tims adapter plate , nose cone mount and driveshaft adapters with our own Design cable shift system.
For the engine we took a 2001 PD130 and added a PD150 turbo plus remap, this normally takes a golf 4 PD150 to 195HP, as we have lost Cat, plus better flowing exhaust and cosworth chargecooler, it should be pushing out around 200hp. 80mph is just a breeze to it.
So here he is.
Quick Vid
http://youtu.be/5Ty4Nt9ea_M
Turbo and mounts

Right hand mount and sump

Exhaust hanger and cradle

MV Engineering-TDi conversion specialist
07989593569-01952 581818
mveservices@hotmail.co.uk
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mazz View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mazz Quote  Post ReplyReply Direct Link To This Post Posted: 22 Aug 13 at 15:21
All in



Chargecooler above gearbox

Dashboard all working correctly

Ground clearence on this lowered Westfalia is around 175 mm to lowest point of bellhousing

MV Engineering-TDi conversion specialist
07989593569-01952 581818
mveservices@hotmail.co.uk
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mazz Quote  Post ReplyReply Direct Link To This Post Posted: 22 Aug 13 at 15:30
Obviously its at original 50 degree angle

Lots of new and shiny stuff
MV Engineering-TDi conversion specialist
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Post Options Post Options   Thanks (0) Thanks(0)   Quote lambretta lee Quote  Post ReplyReply Direct Link To This Post Posted: 22 Aug 13 at 16:36
Cracking ... that looks so much better done than the one I looked at buying .. top work ..
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Post Options Post Options   Thanks (0) Thanks(0)   Quote youthy giblets Quote  Post ReplyReply Direct Link To This Post Posted: 22 Aug 13 at 21:24
Very nice work well done, I guess there's no engine lid mods then? U done away with the egr?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mazz Quote  Post ReplyReply Direct Link To This Post Posted: 22 Aug 13 at 21:41
Engine lid is stock, and all EGR components are in the bin where they belong :)
MV Engineering-TDi conversion specialist
07989593569-01952 581818
mveservices@hotmail.co.uk
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Post Options Post Options   Thanks (0) Thanks(0)   Quote jason k Quote  Post ReplyReply Direct Link To This Post Posted: 22 Aug 13 at 21:49
Mazz is it Keith's van?
Bcs shallowest surf award winner 2006
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aberdare. south wales
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mazz View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mazz Quote  Post ReplyReply Direct Link To This Post Posted: 22 Aug 13 at 22:04
Yeah it is Jason, he has it back in his possession now at last, It has been real hard work to get the bus to a standard I want, Keith lives 200 mile from me so I had to be sure that once he picked it up, it would be 100% reliable.
We over engineered everything and every time we time we did something we thought of a better way of doing it, some jobs on that van we redid three times. But so happy with end product, it drives as you would imagine a T3 to drive if they were still being built today :)
I was truly gutted to hand it back over :(
MV Engineering-TDi conversion specialist
07989593569-01952 581818
mveservices@hotmail.co.uk
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mrhutch Quote  Post ReplyReply Direct Link To This Post Posted: 23 Aug 13 at 00:33
Thumbs Up

even I would ditch petrol/LPG for that
T3 1981 Westy Vanagon - thinks lubricant is a fuel
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Post Options Post Options   Thanks (0) Thanks(0)   Quote youthy giblets Quote  Post ReplyReply Direct Link To This Post Posted: 23 Aug 13 at 08:58
Originally posted by mazz mazz wrote:

Engine lid is stock, and all EGR components are in the bin where they belong :)


That's the way to do it! The upside down Audi box is going to give these old vans so much more life, numerous engine conversions are now doable at a sensible price ; )
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Post Options Post Options   Thanks (0) Thanks(0)   Quote randolph57 Quote  Post ReplyReply Direct Link To This Post Posted: 23 Aug 13 at 13:00
Depends on your definition of 'Sensible' - savings on gearbox are surely offset by donor price/fitting costs especially if utilising clock set/switchgear/tdi geniuses!
Now how do I tell her indoors I need a change to my AFN?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Kent Joker Quote  Post ReplyReply Direct Link To This Post Posted: 23 Aug 13 at 17:17

<font face="Times New Roman" size="3">

<p style="margin: 0cm 0cm 10pt;" ="msonormal"=""><font face="Calibri">So I guess it’s about time I chipped in, I’m the very lucky
owner of this WestySmile and will add to the post with all the highs and lows, feel free
to ask any thing you want to know,<o:p></o:p>

<font face="Times New Roman" size="3">

<p style="margin: 0cm 0cm 10pt;" ="msonormal"=""><font face="Calibri">I will just start by saying a massive thanks to Mario and
Daz from MV Engineering Telford for<span style="mso-spacerun: yes;"> 
</span>creating what must be one of the best T3 in the country,<span style="mso-spacerun: yes;">  </span>we have defiantly had our fair share of ups
and downs and what looked like an unfinishable project is finally back in my
hands.<o:p></o:p>

<font face="Times New Roman" size="3">

<p style="margin: 0cm 0cm 10pt;" ="msonormal"=""><font face="Calibri">So I bought my Westy Atlantic back in late 2011 with a semi
knackered AAZ conversion and thought it’s in desperate need of a mechanical up
date and after reading lots of info decided that an AFN and a rebuilt standard
5 speed box with longer crown wheel and pinion seem to be about as good as it
gets, with in a feasible budget, <span style="mso-spacerun: yes;"> </span>at the
time was and still is an excellent conversion choice.<o:p></o:p>

<font face="Times New Roman" size="3">

<p style="margin: 0cm 0cm 10pt;" ="msonormal"=""><font face="Calibri">So after being off work for Christmas 2011 2012 and contemplating
the various issues of my pending conversion the gear box seemed to be the weakest
link and I say this because I was lucky enough to have a previous bus of mine
Subaru converted, I had the box re built and as anyone knows who had one done
they don’t come cheap, if you want to put big injectors in your tdi and remap
it the poor old box is really on its upper limits of not only usability but
reliability. <o:p></o:p>

<font face="Times New Roman" size="3">

<p style="margin: 0cm 0cm 10pt;" ="msonormal"=""><font face="Calibri"><span style="mso-spacerun: yes;"> </span>Buy comparison the
Passat box was designed by VW to do 500,000 miles without so much of a crunch
and more importantly cope with a modern tdi torque,.<o:p></o:p>

<font face="Times New Roman" size="3">

<p style="margin: 0cm 0cm 10pt;" ="msonormal"=""><font face="Calibri">So spoke to Mario who was keen to give it ago, <span style="mso-spacerun: yes;"> </span>but getting there was far from easy, To be
fair I’ll be the first to admit <span style="mso-spacerun: yes;"> </span>I am <span style="mso-spacerun: yes;"> </span>a bit fussy and had high expectation and definitely
<span style="mso-spacerun: yes;"> </span>wanted to keep the engine hatch totally standard,
<span style="mso-spacerun: yes;"> </span>I wanted to be able to push the cruise
control at 70mph and get good mpg and was also very tempted by all the benefits
of a modern instrument cluster which <span style="mso-spacerun: yes;"> </span>looks awesome at night, MFA read out, fuel
range average mpg next serve indicator, flipped blade key, <span style="mso-spacerun: yes;"> </span>modern immobiliser system, be able to go to
Volkswagen any were in Europe and have it serviced, plug it in to their
computer if there any issues, the hydro mounts are something else, and as many
parts as possible are off the shelf parts so should be able to buy most consumerable from your local dealer.<o:p></o:p>

<font face="Times New Roman" size="3">

<p style="margin: 0cm 0cm 10pt;" ="msonormal"=""><font face="Calibri">I know there are some sceptics out there who have reservations
<span style="mso-spacerun: yes;"> </span>about the flipped gearbox and hands up
they may be right, only time will tell, <span style="mso-spacerun: yes;"> </span>getting it fitted and working is the hard part,
<span style="mso-spacerun: yes;"> </span>if it went bang this time next year its
£100 for another one from your local dismantler delivered !<o:p></o:p>

<font face="Times New Roman" size="3">

<p style="margin: 0cm 0cm 10pt;" ="msonormal"=""><font face="Calibri">It’s all very impressive to look at all the shiny bits and I
have just mot it this morning and everyone that works there was all over it,
well impressed, but driving it is a whole different experience <o:p></o:p>

<font face="Times New Roman" size="3">

<p style="margin: 0cm 0cm 10pt;" ="msonormal"=""><font face="Calibri">It’s really hard to put in to words there’s so much that I
like about it, but it’s weird it feels unmodified if that makes sense I’ve been
in to car and vans for years and have had my fair share of modified cars and
you always feel like they have been modified, some better than others, they
seem to <span style="mso-spacerun: yes;"> </span>become much more of a compromise
which this doesn’t, it just feels like you picked it up from your VW main dealer <o:p></o:p>

<font face="Times New Roman" size="3">

<p style="margin: 0cm 0cm 10pt;" ="msonormal"=""><font face="Calibri"><span style="mso-spacerun: yes;">  </span>it’s a bit like
being able to ring Volkswagen direct and just order a brand new T3 its smooth
and quite like a water boxer, and has two personalities drive it off boost and
its effortlessly goes about its business <span style="mso-spacerun: yes;"> </span>and if you’re in a hurry it’s a bit like and I
know its sound stupid but I<span style="mso-spacerun: yes;">  </span>have driven a
lot of cars over the years and it was bugging me which one it was most like,
but if you’ve ever driven an Audi RS6 the first time you
in a hurry and <span style="mso-spacerun: yes;"> </span>the turbos spools up it
totally <span style="mso-spacerun: yes;"> </span>catches you out and wasn’t at all
what you expected <span style="mso-spacerun: yes;"> </span>the fronts in the air
and all that weight suddenly <span style="mso-spacerun: yes;"> </span>gone, and
the scenery rushing buy seem so wrong but so right, a massive wave of <span style="mso-spacerun: yes;"> </span>torque and totally not what you were
expecting, <span style="mso-spacerun: yes;"> </span><span style="mso-spacerun: yes;"> </span>it’s not golf GTI quick it has that big car
feel <span style="mso-spacerun: yes;"> </span>a bit like a motorway cruiser.

<font face="Times New Roman" size="3">

<p style="margin: 0cm 0cm 10pt;" ="msonormal"=""><font face="Calibri">so if you’re still not convinced, on the way to the mot centre
this morning, after an enthusiastic blast down a dual carriageway I lost all
power and it cut out and wouldn’t restart, expecting the worst, <span style="mso-spacerun: yes;"> </span>I called Mario and the first thing he said”
don’t worry if you can’t get it sorted ill chuck some tools in my van and come
straight down” which from Telford is just over 400 miles round trip so much appreciated,
top bloke top quality installation and excellent after care.<o:p></o:p>

<font face="Times New Roman" size="3">

<p style="margin: 0cm 0cm 10pt;" ="msonormal"=""><font face="Calibri">Like a twat I ran it out of fuel, the fuel gauge is running
in reverse for the next couple of weeks Mario wasn’t able to sort it in time
for this weekend and I wasn’t thinking about it being something so obvious.<o:p></o:p>

<font face="Times New Roman" size="3">

<p style="margin: 0cm 0cm 10pt;" ="msonormal"=""><font face="Calibri">All I can say is get saving, and get yours booked in, it’s awesome!!!<span style="mso-spacerun: yes;">  </span><o:p></o:p>

<font face="Times New Roman" size="3">

<p style="margin: 0cm 0cm 10pt;" ="msonormal"=""><font face="Calibri">It totally exceeded my expectations and anyone that know me.
that was never going to be easy.<o:p></o:p>

<font face="Times New Roman" size="3">

<p style="margin: 0cm 0cm 10pt;" ="msonormal"=""><o:p><font face="Calibri" size="3"> </o:p>

<font face="Times New Roman" size="3">

<p style="margin: 0cm 0cm 10pt;" ="msonormal"=""><font face="Calibri">I’m off to Car Fest in Basingstoke in the morning, and will
be exhibiting on a VW bus stand so if your there come and say Hi.

<font face="Times New Roman" size="3">









Edited by Kent Joker - 21 Oct 16 at 23:15
Keith

1990 PD TDI Westy Atlantic
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Post Options Post Options   Thanks (0) Thanks(0)   Quote scoody Quote  Post ReplyReply Direct Link To This Post Posted: 23 Aug 13 at 22:24
Love the standard of the conversion, I have an AFN Audi A4 waiting to give new heart and lungs to my 89 diesel, Tim's 50 deg plate will be the go but I am keen to get rid of the harshness and noise of the old 1700. Do you think the hydro mounts are worth the extra effort of fitting? I have done quite a few Land Rover conversions as a business in the past and the wrong mounts produced some nasty vibration issues in some vehicles so I am keen to make sure it won't happen on the T3. I posted about using the Audi exhaust but see you have a standard position system, is it reasonably quiet? 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote youthy giblets Quote  Post ReplyReply Direct Link To This Post Posted: 23 Aug 13 at 22:28
Right a couple of points from me;
No.1 your a very very lucky man bet your well chuffed
No.2. Mario you and your crew are very very clever men (Aidan did sing your praises to me!!)

I have been waiting eagerly for the last couple of years for someone to complete a really good pd install and at last it's arrived! Unfortunately I won't have the funds in the near future to get one myself but maybe one day!

Date I ask the rough install cost?ofcouse I understand it won't be the cheapest conversion due to all the development work but you guys have certainly brought the T3 into a very new lease of life. 200bhp in a van shaped liked a brick
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mazz Quote  Post ReplyReply Direct Link To This Post Posted: 23 Aug 13 at 23:13
Cheers for the comments all :-) its been emotional, I am not one fro shedding tears but when I drove this van I reckon if my balls where just 1mm smaller in circumference I would of cried like a big sissy girl, it's that good. it even exceeded my expectations
I am in process of costing this job correctly and will post up price as soon as I have worked it out correctly.
As for mounts they make a huge difference to how this van feels, far superior to the stock T3 mounts, as I mentioned earlier we will soon be stocking these parts here in the UK as currently we have been shipping them in from the FAST in the states, and then modifying them to suit once over here,
MV Engineering-TDi conversion specialist
07989593569-01952 581818
mveservices@hotmail.co.uk
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mazz Quote  Post ReplyReply Direct Link To This Post Posted: 23 Aug 13 at 23:39
Something I forgot to post up here was gearbox bell housing, as we was planning to run this van with at least 190hp and around 300ilbs ft of torque from the start I was very concerned about making everything as strong as possible, once you flip a Passat box you have a issue of having to cut a huge hole in bell housing to remount starter motor, to combat this we cut out a second starter housing from another bell housing and welded it back in as below

No hole and addition of extra mounting points

Worked out really well, plus I now gain three extra fixing points for bell housing to Tims adapter plate

I stripped gearbox and had bellhousing milled by machine shop to same tolerance as factory drawings 0.01mm,

Edited by mazz - 23 Aug 13 at 23:42
MV Engineering-TDi conversion specialist
07989593569-01952 581818
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Post Options Post Options   Thanks (0) Thanks(0)   Quote fufflenarnia Quote  Post ReplyReply Direct Link To This Post Posted: 24 Aug 13 at 09:58
Wow, that is a thing of beauty - loving the engine mounting.

I'm impressed with your ground clearance - how did you manage 175mm? I found it hard to balance between drive shaft angle (clearance of the wishbone) and keeping the sump/gearbox levelish. I now have good ground clearance (just measured it - 140mm) but on standard springs and oversize wheels and tyres (I like riding high luckily!)

More pics please, they belong on the garage wall......

Edited by fufflenarnia - 24 Aug 13 at 12:04
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Post Options Post Options   Thanks (0) Thanks(0)   Quote VW Nerd Quote  Post ReplyReply Direct Link To This Post Posted: 24 Aug 13 at 22:16
Great work MV engineering. I'm really pleased to see that you saw this job through. So many problems to overcome with engine choice, clock set etc etc.
Loving the addition to the flipped Audi gearbox with welded on starter motor housing. Real attention to detail.
So is this going to be the first of many super hot PD buses rolling out of your work shop?

Which gear box code did you go with on this project as the PD boxes are even taller than the ones fitted to the AFN powered cars? Did you go for 5 or 6 speed?
Hope to catch up at VF.
Tim.
Developing parts for the VW T3 TDI market Inc flipped audi gearbox install parts.

Tim Shettle
www.ultimate-engineering.co.uk
Bristol

Tel/txt 07810 320 464

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Post Options Post Options   Thanks (0) Thanks(0)   Quote molecatcher Quote  Post ReplyReply Direct Link To This Post Posted: 27 Sep 13 at 19:56
I have just had the pleasure of a ride in Keiths Westy, well I just do not know where to start, the power is awesome, so smooth, no rattles, and you can talk to each other at near illegal speedWink, the engine bay looks factory,but better if you know what I mean,MV Engineering you have done a first class job and I and many other brickies look forward to a price for this conversion.
thanks for the ride KeithSmile
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Post Options Post Options   Thanks (0) Thanks(0)   Quote panalvan Quote  Post ReplyReply Direct Link To This Post Posted: 08 Feb 14 at 18:17
Big thanks to Keith for letting myself and Andy take a ride this morning in this very we'll sorted van and to experience the gear shift using the cable system .We will both be going down this route as it's 100 times better than our current system we are using on our flip box conversion .looking forward to enjoying my afn tdi conversion once I can find all the gears .Once again thanks a lot Keith catch up at a show soon
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