1980 VW T3 DoKa |
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surf dude
Yardie Joined: 11 Apr 05 Location: United Kingdom Status: Offline Points: 470 |
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Posted: 22 Nov 12 at 22:51 |
Right, lets see if this works. This is my thread from Retro-Rides, I'll drag stuff across, so it may be a bit disjointed, but I thought it was about time I got it up here
Welcome to my Double Cab! 28 July 2010
I've had this for a while now, haven't done a lot to it yet, but allow me to introduce the 'Fish Van'!! (Might be a good idea to grab a brew, this could take a while ;) ) I bought the van when I was serving in Germany and imported it back to the UK when I moved back here in 2000, this is what it looked like back then, It's a very early van, but had much more modern running gear fitted, like a 5 speed box, 2.1 fuel injected DJ engine (112 BP) and power steering and had been 'customised' with a checker plate load bed, stainless side panels and a nice load cover, lowered on 17" Borbet A's. I loved it, but my then girlfriend (now wife :) ) wasn't quite so keen, hence the name of the fish van ::) So we ran it for a while, I was commuting weekly in it 125 miles each way, bit pricey at 20 to the gallon but hey ho, I still had money from my Germany days so all was good. I'd left a 2 door Taunus (Mk 5 Cortina) in Germany that I was mid way through restoring so I decided to drive over, buy a trailer and bring it back and that was when it all started to go a bit wrong ::) It broke down about 15 miles outside Calais, I had no tools no phone and wasn't even sure I had roadside cover. Fortunately my mate who was driving over at the same time drove past and stopped, lent me his phone and the long trip back home via 3 recovery trucks, a tractor and a lamp post began. The engine was trashed, so ideas of ever getting the Taunus back were binned ( It broke my heart ringing my mate who was storing it and asking him to get rid of it. It was solid as a rock and I'd had it for 8 years :'( ) and had a brand new engine fitted to the van. It never ran right even with a new engine and with too many visits to the garage and swiftly running out of cash I eventually sold it to a mate for the cost of the engine. I've always had a van since, but always said if the DoKa came up for sale I'd have it back. And then, on this very site last year there it was http://retrorides.proboards.com/index.cgi?board=FSW&action=display&thread=69830 two weeks later, it was back on my drive, looking a bit sorry for itself, and it's been attacked by the old rust a bit, so there's plenty to do, but now the new garage is built and the Pug is 'nearly' done ::) and the Merc has sold I don't have any excuses not to get cracking on it. Anyway, Pics ;) Now in silver, not the best spray job, it's pretty thin in places and will need redoing Golf GTI interior, Mk 2 I think, Projekt Zwo steering wheel, horrendous wiring and carpeting and hideous gear knob. Comfy though, but the new seats are a bit higher than before so can't see the dash properly ::) Ermm ??? And rust :( (Interestingly I've never seen another van with more than one set of vents, so need to keep them) I think these front arches are extended, so this repair should be interesting as well. There's more rust, some of it quite bad, but the underside is thick with underseal and when I sold it it was immaculate so I'm hopeful that its solid and the rest is . I love how it sits, looks mean ;D I have lots of plans, but at the moment I'm waiting to hear back from the garage to see if they've fixed it yet ::) I've just had to replace the water pump, and now it's started randomly cutting out >:( I'm seriously hoping that it isn't going to be a lemon, but I have a sneaking suspicion that it's a bit intoxicated that I got rid of it in the first place ;) 20 Sept 2010 So, time to make a start on this as the 205 is 'nearly' done and I need to make the most of being at home for a bit. So first off, the back has 4 nice bits of stainless steel on for the bed, Stuck down with entirely too much mastic! Didn't do a very good job of keeping the water out though and whoever thought it was a good idea to use MDF to seal the roof of the locker needs their head examining! And it stank! So, crowbar, saw, screwdriver, drill and obligatory swearing saw the stripping begin ;) All wood stripped off and binned ;) This is in really good condition, and the underbed locker has minimal rust as well. The mould from the damp wood needs cleaning, and then it'll be mint :D This is the worst bit so far, where the water ran down the bulkhead and rotted the wood above it ::) still a quick whizz with the wire brush and it should be fine ;) So good to finally be making a start on this. More to follow 24 Sept 2010 So, a bit more done, I've started to tackle the scabby bits, first bit was the locker door opening, Not to bad, it'll need a bit of welding, I just need to dig some sheet steel out, and get some etch primer and stuff, so moved to the wheel arch, Actually not looking too bad, and only really surface which bodes well for the rest (Fingers crossed) Then as it was getting late, I had to ditch the drill, so thought I'd have a look at the doors and door panel, as that was pretty shagged, Door is mint, shame about the panel ::) Then had a shift around to make room for the new arrival ;) More to follow ;) 23 Jan 2011 So I've been thinking about the interior a lot and what I want to do with it so thought I'd make a start..... No I haven't done any more to the outside but I don't like to work in a logical order ::) First thing was to take the rear seat frame out. It was bolted through the floor, which means the side with the door is easy but the other side, on your own isn't ;) RR ingenuity :) Remember this? Well it was glued, screwed and masticced in, what a PITA to get out ::) But out it came, carpet and wooden floor up and it doesn't look too bad ;) Bit of wire brushing bought this out, but overall I'm pretty pleased with the condition of it :) Couple more weeks till I'm home again ::) but more to follow then. 24 Jan 2011 So, managed to get a bit more stripping done. Now all the carpets are out, and most of the dashboard plastics are off as well. Need a new fuse box cover and some repairs to the steering cowling, but I'm thinking of getting them flocked so some superglue/araldite should sort that out. Dashboard is in a right state, holes, dents, rivnuts, you name it! Still, that needs to come out but not right now! Wanted to try the Subaru seats in there to see if they'd fit, and with a bit of jiggery pokery I reckon they will. So, sit one on the drivers side, with the small piece of moulded carpet for the footwel.... ;) Mojo booster :D 3 more weeks til I'm home again though ::) 22 Feb 2011 So, I set to the van with various methods of rust removal... The screwdriver! And the angle grinder with abrasive pad! Its all a bit scary! Then I got sick of breathing in dust so locked the garage up and took the Escort down to the 8 Ball opening night in the lashing rain! I'll get back in there next weekend :( 02 June 2011 My 205 takes up most of my tinkering time, so, sick of it I evicted it into the rain (behind my Scooby donor) Onwards...... So, remember this? I thought it didn't look too bad..... Oh dear, it would appear that I was wrong ::) First off, I got a spot weld drill and started taking the floor out, Underneath, well its a bit rustier than I thought! The piece above the jacking point looks like it was repaired, and I use the term loosely, with stainless steel, held in with a couple of spot welds and a lot of mastic ::) It's completely rusted out the chassis rail and the bottom of the B pillar. Damn und blast as the Germans would say! Pics I've done a bit more digging, mostly of filler and Mastic. Seems the sill was repaired with the same stainless steel as the back was covered on, but the garage now has a fine coating of filler dust ::) I thought I'd dig around the floor in the locker while I was at it! Big mistake :( And as if that wasn't depressing enough I thought I'd take a look (read, the wire brush) at this.... Oh dear I was dreading this as they're extended by about half an inch over standard! No idea how, but standard ones aren't wide enough to cover the wheels so I'll need to repair or replace.... 27 Aug 2011 Blimey, been a while but between dropping the engine on the Escort, keeping trying to get the 205 running and life, this has taken a bit of a backseat ::) But, I want to take it to the Gathering next year so I need to get on with it. I did some more rust removal drilled out the welds on the locker door stop, Oh dear :( Then decided to slice a hole to connect up the holes :o We're here now, with me looking at it, and repair panels thinking where the hell I go next! I've made a few decisions on stuff, but you'll just have to see how it pans out ;) That'll do for now. I'll do a bit more cut and paste in a minute. Enjoy. Pete |
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Too many projects..... Not enough time!
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surf dude
Yardie Joined: 11 Apr 05 Location: United Kingdom Status: Offline Points: 470 |
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Right, I'll skip some stuff now, and bring it up to date.
Stripped the Subaru for its engine, seats and stereo. So managed to do a few bits and pieces after sorting the 205 (well, actually, I'm sharing time between the 2 ::) I just change when I've had enough of one or the other ;) ) First of all I bit the bullet and chopped the wheelarch out :o I have a spare, which I've cleaned up. It's still in need of a tweak, and the old arch was rolled, so I'm contemplating whether to try and do this before or after fitting. I've also been looking at the rest of the side and I have come to the conclusion that I may have to chop some more bits out :( The rust is pretty bad and I figure why patch when I can replace? I dropped the door, as it was just getting in the way, and had a dig round the chassis leg Yep, there are a few holes there ::) Its a shame as when I had the van before it was all like this underneath, but where its been painted with that horrible black crap (no prep, just plastered on) I think it's retained the water and rusted from the inside! :( 22 Nov 11 I have the week off, so after having a bit of a clear up, I started inearnest on the van! First thing though was to build a metal folder using Tony BMW's plans over on the "making panels" thread! Had a few issues but I'm well happy with the result, and I got the chance to warm up the welder without worrying too much about the welding ;) Not pretty but more than capable of doing the job :) I've been running the grinder round the bottom of the B post, not to mention spending a lot of time staring at it! I looked all over the net to see what the jacking point looks like, but no joy. In the end I swallowed (Gulped) and bought a new chassis rail. Now this might seem a bit excessive, but I spent so long prevaricating about it that in the end I just thought sod it! Here it is I just need to have a look at the back end as I'm pretty sure it's nice a solid, which is good, it'll save me doing the rear suspension :o I made a decision yesterday though that I would start at the front and work my way back. I'd already chopped the rusty front wheelarch out, had a new one (which went back as it was shocking) and got hold of a chopped one. I started to get it apart to see what sort of nick it was in. One problem with buying chops! They tend to be just as rusty as what you already have ::) Anyway, I stripped it down, gave it a tickle and decided that this was the ideal opportunity to get rid of the fuel filler (No, it won't run on air sadly :( I'll be fitting another!) Template, chopped a bit out, then did it again, fettled, welded and ground down. I'm actually pretty happy with it, I even got to use my new panel beating hammers to put in the curve! Sadly, I'm not to happy with that bit so I may chop it out and take a piece from a rear wing I have. I'll look at it tomorrow and see how it looks with a fresh set of eyes. It's not welded in yet, just sitting there. Mojo booster ;D Oh, and this arrived!! 19 Dec 2011 Quite frankly, the more I look at this the more petrified I am at what I've taken on. Still, I took a large dose of "Brave" and got stuck in! I started here Then got the grinder and hack saw out an chopped out the offending piece. Yep, I could have repaired the holes but I just didn't know what was behind it! Now I know!! And that appears to be no rust :) Now I understand how it goes together, I tickled the hole and the repair piece, 12 Apr 12 Well, more chopping today. I've had a variety of tools out to try chopping bits of rusty metal. The grinder's just too big ::) I took some pics with a decent camera as well ;) The wheelarch is all out now, didn't take a picture of that, no idea why, but here are a selection. The random strip above the inner wheel arch? It looks like it was ripped, seriously, even I can cut straighter than that!!! Then the front piece had to come out. It's rusted out at the bottom, but also on the inside, there was no other way to get to it (honest) so more choppy choppy cutty cutty ??? This bit has me worried, it's where the panels all meet, but it also forms a major part of the chassis structure. Problem is, it's going to have to come out which means new jacking point, which the back wheel swingarm attaches to...... I keep loooking at it thinking "I think I might have bitten off more than I can chew here" Oh well, you live and learn right? I had a bash at the door yesterday, I'm thinking about getting the doors dipped? What do you think? I'd like to get the whole thing done really, but I don't think the budget will stretch to that, not to mention the fact that if I strip it to the point where it can get dipped, it will never go back together ::) To drag myself away from just staring at it, I had a play with the fuel cap I bought off of eBay. It's for a Golf, I thought it might fit! Yeah, right. After dismantling the old locking cap and putting the insides into the new one, I couldn't get the key out when it was locked, only when it was open ??? After much staring, I tried another tack. Take the old cap, put it in my lathe (read, pillar drill) and start to thin it down using various methods so it can go inside the alloy cap. After a bit of faffing, it's done. This is locked onto the inner part that connect to the fuel filler pipe I'm happy with that although the key hole is a bit too far in. It still works though ;). It'll get recessed into the wing where I have already deleted the old hole. One day ;) 07 Sept 12 Back from Australia a month and there hasn't been a lot of progress either ::) I have a man coming to give me a quote on some of the repairs and it'll be off to their shop soon! I have done a few little jobs on the hack job wiring and cleaned it all off so the garage can see it properly. It was a bit of a mojo booster, and I have time now to crack on with it. Updates will be coming soon ;) and the album of the rust is here if anyone's interested. http://s1204.photobucket.com/albums/bb405/Transglobe2010/DoKa%2030%20Aug%2012/?start=all 11 Sept 12 Well, I'm still waiting on the body man ::) Meanwhile I've carried on tinkering whilst doing the list of 'Jobs' SWMBO left me as she headed off to China for work ;) I've been trying to take out the back door glass, and after some not very helpful advice on the internet, I was looking at it last night and at the extension lead next to it thinking 'maybe that will work'. I got the lead into the rubber enough so that it wouldn't hold the window in and gave it a shove. Well quite a bit of shoving actually, but it worked. Result. But why have you taken the window out Pete? Well, because, many moons ago they were tinted, and with many years of sun they have now faded away to clear. And I want them tinted again. Obviously tinting over the top of the old stuff isn't an option, so I have employed various methods to try and peel it off. Heat gun, white spirit and the sharp blade. A combination of all seems to work best, but it takes forever and is a bit painful on the old fingers ::) Nearly done, only 4 more to do!! 25 Sept 12 I've had a couple of days on the van, refitting the doors so that the bodyshop have something to line up the new stuff on as well as sorting out the smaller patches of rust as I go round the van. Both side windows are out, so gave them a tickle with the Dremmel (my new favourite tool) the drill and the angle grinder as they had rust coming through in the bottom of the frames. Front panel There was a bit of rust poking out under the windscreen seal, and as these are well known for rotting out I used the foot against screen method to remove it. Turned out badly >:( >:( Not happy, a tinted top screen is a, expensive and b, like rocking horse pooh. I can get one with a tint and aerial, but that's £380 out of the budget. I am a little bit pee'd off! Still, it wasn't all bad as the rust was fairly minimal. I've ground it out, now I'm undecided on how to repair them. Actually, I know full well what I need to do, I'm just putting it off!! I also drilled through the spot welds on the LHS locker door catch to have a look at the chassis rail etc on that side. Mmmm,looks familiar ::) But, Looks more like surface rust, so I'll finish off the other bits and then cut a bigger hole and get in there with a brush! Oh, last bit. I whipped the headliner out to have a quick check on the rust up there. It all looks good apart from Aerial hole ::) The rest is all pristine though, and this is only surface rust I think. More digging later! Been fettling the 205's exhaust today, mainly so that I could get it out of the way of the pit (I need to get under the van to take off the fuel tank) so I took the opportunity to give the garage a good sweep out and tidy up the boxes of crap! Pug out of the way, I turned the key and it fired up straightaway! Sounds like a bag of nails mind, not sure if it's the exhaust blowing or something more sinister.... Still it moved under it's own steam! Looking good ;D Forgot how low it was at the back! Been so long since it's been on it's wheels, and been able to get round the back too!! More tomorrow. 15 Oct 12 Well, a very nice guy came today to take it away...... To the bodyshop. It's a bit tight round the back of my house ;) F@#k knows how I'm going to get it back in the garage! I guess I'll be trying to fit the new fuel tank outside the front of the house!! (Or a plastic bottle substitute, should get me round the back before conking out!) Don't worry, he did tie it down properly before he left ;) He brought the body man as well, so I could tell him what I had done! He looked a bit ::) (He was probably thinking, oh no, another wannabe with an angle grinder went too far!) He's probably right ;) So, They have it for 50 hours of labour and I've said to them to see how far they get. TBH, as long as the RHS gets done I'll be happy. We'll have to see. So, that's us up to date! It's still at the body shop, the RHS is doen and they're now on the LHS. No pictures, although I think they've been taking some as they go along. There will still be some small jobs to do, but the big and scary stuff will be done. Hope to have it back before Xmas (fingers crossed) Thanks for looking in, Pete |
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Too many projects..... Not enough time!
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Ladybird
Groupie Joined: 22 Aug 12 Location: Ireland Status: Offline Points: 126 |
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Surf dude nice work and cool history keep it coming
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surf dude
Yardie Joined: 11 Apr 05 Location: United Kingdom Status: Offline Points: 470 |
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Thanks mate, you read that all pretty quick I'll add stuff as it happens, there is other stuff going on and I'll keep those updates coming! Pete
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Too many projects..... Not enough time!
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asw75r
Groupie Joined: 28 Oct 09 Location: Uddersfield Status: Offline Points: 55 |
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my cc looks the same around the rear, the seams before had no rust in them to indicate what was under the surface, but once you start digging . . . . when its done though you will know its good for a good while
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T3Panel
Vanorak Joined: 18 May 10 Location: Surrey Status: Offline Points: 1815 |
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Wow, finding rust like that would make me want to throw in the towel. Fantastic job! It's going to be great when it's all done, keep up the good work
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1987 T3 Panel 2.0 T3i!
1990 T3 Atlantic 1.8T Conversion sat on an engine stand waiting for spare time. |
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StvC
Yardie Joined: 21 Feb 10 Location: Wolverhampton Status: Offline Points: 587 |
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Finding rust like that would make me stop looking. Fook that. Fair play to ya though.
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Die Deutsche Doppelkabine ist sehr gut. 150bhp planned
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surf dude
Yardie Joined: 11 Apr 05 Location: United Kingdom Status: Offline Points: 470 |
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Lol, yep, I kinda felt that way and if I didn't have such an emotional attachment to it , I would indeed have thrown in the towel!!! It's a keeper though, so I might as well get it done properly, then, like you say, it'll be nice and solid. More to come over the weekend.
Pete
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Too many projects..... Not enough time!
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max and caddy
Vanorak Joined: 12 Dec 09 Location: Lancaster..uk Status: Offline Points: 4866 |
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Interesting stuff....makes me hungry for more rust....!
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T3ADICT
Vanorak Joined: 21 Jul 05 Location: LeightonBuzzard Status: Offline Points: 4215 |
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the lower 4 to 6 inches of my tristar has lots of rust. more than yours..
your crewcab started out life as a aircooled, only the aircolled crewcabs had the 3 sets of rear vents.
you dont see many aircooled crewcabs or single cabs..
most of the ones i have seen here in the uk are breaking only, there was one on ebay for a fair while that never seemed to get any bids.
while you are doing lots of welding maybe think if you would like to ad the 4 door.. yours being a lhd makes it easier here in the uk.
i think i have even seen someone selling the complete cut out section on ebay.
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WHY T3's.... because they are just so adictive, and having one just aint enough
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surf dude
Yardie Joined: 11 Apr 05 Location: United Kingdom Status: Offline Points: 470 |
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[
Ha, well, there's more where that came from! Hopefully I can get some images from the bodyshop soon. QUOTE=T3ADICT] the lower 4 to 6 inches of my tristar has lots of rust. more than yours..
your crewcab started out life as a aircooled, only the aircolled crewcabs had the 3 sets of rear vents. you dont see many aircooled crewcabs or single cabs. most of the ones i have seen here in the uk are breaking only, there was one on ebay for a fair while that never seemed to get any bids. while you are doing lots of welding maybe think if you would like to ad the 4 door.. yours being a lhd makes it easier here in the uk.i think i have even seen someone selling the complete cut out section on ebay.[/QUOTE] Yep, figured that it was previously air cooled, like you say, you just don't see many of them around. I had thought about doing the other door but I have plans for that side involving amp, speaker and maybe a tv! Oh, and if your van has more rust, I feel your pain Is there a thread on it? |
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Too many projects..... Not enough time!
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surf dude
Yardie Joined: 11 Apr 05 Location: United Kingdom Status: Offline Points: 470 |
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Sooooo, the 50 hours has been and gone, the RHS is finished ::) and they have now moved onto the other side and front panel!! They reckon another 5 or 6 hours should have it done, so the budget is now.......... Well, growing!! Still, it's a keeper, but I'm still stood here thinking that I could have bought a better base!! (BUT, we do have history together!!) So, no pictures yet of the van, the guy has done a nice job though, I'm going to have to try very hard to replicate his work on the other side ;) A shiny new fuel tank arrived. Bit bent, but hey ho. A quick tap with the hammer, and it looks a bit better. It'll get some more paint too, It needs to last another 30 years..... Meanwhile, surfing the interweb a couple of weeks ago threw up an advert for an Ej20 Subaru engine, fitted with all of the necessary bits and running Megasquirt. Removed from a T3 to be used in the guys van but never used, he was selling it for what was a pretty good price. So a quick chat with the bank manager (SWMBO) who suggested that I price up the parts I'd need for my current Scooby lump and megasquirt, EDIS etc and exhaust for the WBX 2.1, both of which would be about the same........ So, I went and picked this up. I now have a box of bits, lots of wires (fortunately they are labelled!!) and a certain amount of trepidation about making it work ::) Nothing new there then ;D
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Too many projects..... Not enough time!
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surf dude
Yardie Joined: 11 Apr 05 Location: United Kingdom Status: Offline Points: 470 |
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So, as well as doing a ton of DIY, I've spent a bit of time in the garage. The bumpers were looking a bit iffy in places, and it looks like they're plasticoated, And that looks like they're galvanised too ;D After a bit with the heat gun and scraper the back bumper is stripped. I've done them both now, and hit them with the paint stripper in the grinder. back bumper looks spot on, but the front is a bit 'dented' and rusty!! (Haven't stripped the inside yet either!) Should be alright though. Typically, I'd just polished the Golf and it's now covered in a thin layer of dust ::) Luckily, I sprayed these before though ;) They're the straps that hold on the new fuel tank.
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Too many projects..... Not enough time!
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Mooch
Yardie Joined: 06 Oct 07 Location: North Wales Status: Offline Points: 420 |
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Liking this..... Erm, obviously nice van stuff going on there too, ahem...!! |
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Mooch
1983 T3 Vanagon Westy, 1.9i Watercooled Petrol (Vege recon) |
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surf dude
Yardie Joined: 11 Apr 05 Location: United Kingdom Status: Offline Points: 470 |
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Erm, yes, not too van like but very very awesome. Away in storage at the moment, but every time I see a pic of it I want to rush up to where it is and get it back!! Maybe when I've finished sanding the van down and painting it, when it won't get covered in shit!!
In other news, I made a start on the bumpers. I'll stick some pictures up tomorrow.
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Too many projects..... Not enough time!
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ELVIS
Moderator Group Silence is golden, gaffa tape is silver Joined: 04 Nov 06 Location: Promised Land Status: Offline Points: 9982 |
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tell your supplier to do one.
sourced a top tint and 99.9% sure it had an aerial for a SA bus a while back, change out of £200 fitted! (and was Pilkington)
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Www.justgiving.com/ELVIS-SUMMERS
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surf dude
Yardie Joined: 11 Apr 05 Location: United Kingdom Status: Offline Points: 470 |
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Good to know. Who was it from?
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Too many projects..... Not enough time!
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ELVIS
Moderator Group Silence is golden, gaffa tape is silver Joined: 04 Nov 06 Location: Promised Land Status: Offline Points: 9982 |
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will find out tomorrow chap. think it was about £185 fitted. where abouts in uk are you?
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Www.justgiving.com/ELVIS-SUMMERS
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surf dude
Yardie Joined: 11 Apr 05 Location: United Kingdom Status: Offline Points: 470 |
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Thanks dude, I'm just outside Ipswich, Suffolk.
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Too many projects..... Not enough time!
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Gtavalanche
Vanorak "I'm learnding" Joined: 22 Feb 11 Location: Ipswich Suffolk Status: Offline Points: 1305 |
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Where abouts? I'm at wattisham. If you ever need a hand.
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I taste Hurty!
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