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1980 VW T3 DoKa

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rowlesy View Drop Down
Vanorak
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Post Options Post Options   Thanks (0) Thanks(0)   Quote rowlesy Quote  Post ReplyReply Direct Link To This Post Posted: 29 Apr 15 at 20:05
niiice! im sure you'll fill the unit with other projects to distract you soon enuf! 
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surf dude View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote surf dude Quote  Post ReplyReply Direct Link To This Post Posted: 29 Apr 15 at 20:13
Lol, it's starting to fill up already with all of the crap out of the old garage and loft! Then it'll get the Escort, probably the mini and eventually the T3 shell I bought to turn into a trailer and rear canopy!!!!!! Yep, it's going get filled up alright
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Post Options Post Options   Thanks (0) Thanks(0)   Quote surf dude Quote  Post ReplyReply Direct Link To This Post Posted: 05 May 15 at 23:44
Little bit of work tonight after our monthly East Coast Retro's meet at the Shipwreck in Shotley Gate. Unloaded all of the stuff stored in the pick up bed to get to the engine, the stainless steel had let a bit of water in and stained the ply so need to figure out a way of sealing it all properly, otherwise we'll be back where we started with rotten wood. And I don't want that!



Onto it properly tomorrow and get the new sump fitted.
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surf dude View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote surf dude Quote  Post ReplyReply Direct Link To This Post Posted: 07 May 15 at 23:22
Few hours at the workshop tonight (was there last night too, but that was mostly trying to find an extension lead..... I failed) taking off the old sump and fitting the new one. Easy to see why it pee'd oil all over the place!



Rusty, and the kerb took the patch straight off! Really should have bitten the bullet and bought a new one before I fitted the engine ::)

I wanted to look at the measurements of the oil pick up pipe, and see if there was much adjustment to shorten the sump



Yep, one to think about for the future as the sump does hang out the back and is likely to take a bit of a beating. So, on with the new! Not quite, slightly different flange size, meaning that it's too close to the engine mount, so need to trim that....



Then fit. And take off again and trim the other side..... And refit!



The engine mount is refitted, I now just need to torque everything back up and we are good to go! While the wheels are off I'll probably get some new tyres fitted and refurb the brakes.

Thanks for looking in.

Pete
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surf dude View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote surf dude Quote  Post ReplyReply Direct Link To This Post Posted: 30 May 15 at 18:25
Evening. So, been steadily plugging away while sorting through stuff in the workshop as well as trying to make the single garage at home less cluttered. Selling on my Merc at the weekend as well so won't have a tow car, so really need to get this sorted and on the road!

So, doors off, wheels off and a full going over with scotchbrite. It is looking like its about ready for its next coat of paint, but a, I can't find the paint, and b, it is massively dusty in the new workshop. Next door (who runs a drift car amongst other things) has offered some sheeting so may have to make up a booth of some sort so that it doesn't end up looking like sand paper!! Anyway, as it sits now:





I've also started changing the handbrake cables, which of course don't fit! Cue, emery cloth and files, halfway through that job, and have finished fitting the new sump which is now all torqued up and ready for topping up. It's low though and hangs out behind the line of the rear suspension. I'll definitely need to look at a modified one, but hoping this should do for now!

Back up there tomorrow, but need to check the Escort over before Snetterton on Sunday. Think that might just have a for sale sign on it........
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surf dude View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote surf dude Quote  Post ReplyReply Direct Link To This Post Posted: 24 Jul 15 at 22:50
Oops, been a while so here's a bit of a download.....

Having to start doing some bits on the Mini, but still cracking on with this, really need it on the road, especially as I've just sold my estate with tow bar and bought a mid life crisis coupe......

Still prepping for another coat of paint but in the meantime I need to get some paint onto the rear bed frame



Looks tidy. Next job was to whip the drivers seat out as the handle to move the seat back and forwards wasn't working properly without raising the seat up (it's got a height adjuster! Posh eh?). It needs a couple of things, first off to bend the handle out slightly, and then I need to fix the rod so that it's got something to rotate on. Bit of flat bar cut to size and and another piece over the top, just needs welding now!



And just to prove that no matter how much space you have you'll always fill it.... ::)






Edited by surf dude - 24 Jul 15 at 22:51
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surf dude View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote surf dude Quote  Post ReplyReply Direct Link To This Post Posted: 24 Jul 15 at 22:52
The filler cap!

So, I'd always wanted to do something different with the filler cap, so I deleted the old hole from the wing (not sure that's the right term, but you get me right?) and bought an aero filler cap from kit car parts suppliers extraordinaire CBS.




I measured to find the centre-ish of the panel and marked up so I knew where it would end up.





So, all marked up but I don't have a hole saw that will cut a 62mm hole! So, take a small piece of metal, measure out a gap of 31mm and drill some 2.5 mm holes in it



Drill a pilot hole in the panel and rivet said piece of metal to panel. Then drill in one hole, then secure it with another rivet (but not compressed?) drill, move round etc etc







Yay, it fits! (Well, I'm surprised even if you lot aren't!!) next up, drilling the mounting holes. So, Mark up, re-use the piece of metal, clamp and drill twice,



bolt up, drill remaining holes.......



Blimey, that worked as well! So, a successful couple of hours. Changes to our weekend plans courtesy of Dave Grohls attempts at gymnastics mean that we now have a whole weekend at home, which means we may actually get to throw some paint at it..... Keep watching ;)

Pete
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Post Options Post Options   Thanks (0) Thanks(0)   Quote surf dude Quote  Post ReplyReply Direct Link To This Post Posted: 24 Jul 15 at 22:54
So, today we finally got another coat of paint on after rolling the van into my dust free booth.



I spent one night in the week sealing the floor with watered down PVA, now that's a good thing to know because it's definitely worked, and cut right down on the dust.

So, roller in Denise's hand and foam brush in mine we set to it. Not the best lighting and bound to be a few 'blemishes' but I'm planning on this being the first of two coats before refitting bits and starting to put the van back together in preparation for the summer break (and the Gathering of course!) so, behold, still tacky but looks pretty good so far.







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surf dude View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote surf dude Quote  Post ReplyReply Direct Link To This Post Posted: 24 Jul 15 at 22:55
decided to grab the back windows and bring them home and try the window tint....

First effort was a bit untidy as it got stuck to itself so I'll go back and do that again if I have enough left, second one came out a lot better!





Lol, looking at that I have to explain that it's on a duvet.... And not my very low standards of what I think is good ;) More to do this evening, but wanted to chuck up a quick update!
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surf dude View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote surf dude Quote  Post ReplyReply Direct Link To This Post Posted: 24 Jul 15 at 22:57
So, a weeks holiday and an ear infection later, it was time for the third coat of paint. I'd done the door frames before I went away, and the subsequent winds had blown the farm dust all over the paint, so they look a bit crap! Well, at this point in time it's going to have to be good enough, because there is a month to the Gathering and we're coming in this, which basically means it's time to start putting it back together for an MOT and at least a week of shakedown.......... Ahem!

So today, after a going over with scotchbrite, the next coat of rollered paint could go on. It was hot, but the door had to be shut to keep the dust to a minimum, behold....













The doors didn't fit in my dust shelter but still got a good thick coat.



But probably look like sandpaper, as a gust of wind came in when I opened the door ::) see what that looks like tomorrow then! Might get some door panels covered now that I'm back home!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote LTCamper89 Quote  Post ReplyReply Direct Link To This Post Posted: 24 Jul 15 at 23:22
Looking lovely, and I like the drilling jig. Top lateral thinking.Thumbs Up
1989 LT28 2.4D    Saviour of 6Music, well one of them. Now playing http://www.bbc.co.uk/radio/player/bbc_6music

VW LT Camper not Cramper

....at least the roof is not rusting away....
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Post Options Post Options   Thanks (0) Thanks(0)   Quote surf dude Quote  Post ReplyReply Direct Link To This Post Posted: 24 Jul 15 at 23:33
Originally posted by LTCamper89 LTCamper89 wrote:

Looking lovely, and I like the drilling jig. Top lateral thinking.Thumbs Up


Thanks pal, not my idea but worked well enough! So when I got in last night, I thought I'd try and cover the front door cards. Nothing too flash, got some vinyl table cloth, cut to shape and glued to the door card, then snipped around the outside,



Flip over, glue and done.



They're a temporary measure, I'll do something a bit posher next time!

Then I cracked out the welder and sorted the seat rails (no photo I'm afraid, you'll just have to take my word for it ;) )

Then I thought I'd just start refitting a few bits! Front indicators first. They work! Then fitted the headlights. So do they!! Oh, hang on a minute



The indicators become sidelights when the headlights are on! And that didn't used to happen :( so I mucked about with the dash wiring for a bit and also noticed that the oil pressure gauge rises when the engine is off, and when you flash the headlights. Now, electrics really isn't my strong suit, so I'm going to have to head back up there over the weekend and figure WTAF is going on? Although I had a think on the way home and the tow bar wires may be touching as they're shoved down the inside of the rear valance at the moment..... I doubt it's going to be that straightforward though!

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Post Options Post Options   Thanks (0) Thanks(0)   Quote LTCamper89 Quote  Post ReplyReply Direct Link To This Post Posted: 24 Jul 15 at 23:41
You know it will not be the easy option.

I did think that the vinyl tablecloth could have been a Christmas one, now there is a thought......
1989 LT28 2.4D    Saviour of 6Music, well one of them. Now playing http://www.bbc.co.uk/radio/player/bbc_6music

VW LT Camper not Cramper

....at least the roof is not rusting away....
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Post Options Post Options   Thanks (0) Thanks(0)   Quote surf dude Quote  Post ReplyReply Direct Link To This Post Posted: 25 Jul 15 at 08:45
Well, amazingly it was the easy option!! After separating the wires out it appears that it was indeed because they were all shorting out! Then I spent a couple of hours sorting the lights in the switches, and then realised after I'd soldered a bulb to some wires for the hazard switch that is connected it to the wrong one!! I've identified the proper one though and stuffed it in and then battled through the floods for a night on the couch with the boss!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote surf dude Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jul 15 at 22:54
Few days worth of updates....

Popped in this morning with the boss and spent an hour fitting the doors and have to say that I'm pretty pleased :)





Door handles were manky so stripped them down and gave them a coat of satin black



Then started fitting up the drivers door





Polished up the window winder handles after stripping off the plastic. Really wasn't too sure about the door cards but actually think they look the dogs now!

With?



Or without (wind deflectors)?



Discovered that I hadn't stripped the window tint from the passenger door, so just been doing that. Googled it this time and used the clothes steamer! Still took a while but so much easier!

Cracking on nicely, though last night was a bit of a drag! Finally got the dash pod in and working, even the oil pressure gauge! Fitted the heater control panel, tested it and one of the cables popped off! arrghhhhh I really do hate the heating system on VW's so it'll be a project for the winter to rip it out and put something in that works!



Then I couldn't get the reversing light to work, so sacked it and came home and had a beer!

Tonight was a lot more productive and I've ticked off a few more jobs. Fitted up the passenger door, the rubbers/window seals aren't quite as good on this side so the window moves around a bit when it's wound right down :/ Still, most of the time it'll only be me anyway....



Just need to fit the armrest (when I can track down the screws) and we're done. Now the eagle eyed amongst you will notice that there are no speakers in the doors. Well, there will be, but the on the post MOT list and will get dome of I have time. I can manage without, or I'll just connect a lighter socket to the garage radio and put it between the seats ;)

Next up was the locker doors. There's plenty of balancing the door on your head and lining up the plates that the hinges screw to, and to be honest the first one tried my patience a little bit.... At one stage I even had to crawl in from the other side and unscrew the lock as it got stuck! Luckily, after I'd found the hinges and lock for the other side that one went on a lot easier.





Need to fit all the door seals, just need to get some suitable adhesive. Any recommendations?

Fitted the rear bumper as well, picked up some cheap end caps which are pretty poor, but they'll do for now!

And, you'll have to wait for more pictures because Poxy Bucket has failed! Feeling like I'm getting there now, although there's still a way to go :)

Ah, back on again ::)



And seeing as how we're sort of getting close, I thought it was time to fit my new gear knob. Now, I may have mentioned this before, but I had some left over ply so stuck it together, threw it in the pillar drill and rounded the edges off. Then a few months later one of my brothers got a wood lathe so I got him to shape it a bit more. Fitted it to my extension (oo-er Mrs) and screwed it on.



You may notice the badge in the top? Well, it's actually a 50 Pfennig piece from the days before the Euro, and I've had it lying around for years and always thought it would look cool. And it does, apart from the chunk that came out of the wood on the final pass of the drill to enlarge the hole!! Bum hats ::)



Love it though:)

So, had a spare pair of hands so this happened



Which started well, but ended up with a split in the seal. Not good, but going to try and get a new one tomorrow. The two on the side went in much better, with plenty of washing up liquid it actually was easier than I thought it would be!





oh, and SWMBO votes yes on the wind deflector thingies!



Back on it on Sunday!

Edited by surf dude - 31 Jul 15 at 22:59
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Post Options Post Options   Thanks (0) Thanks(0)   Quote donecan Quote  Post ReplyReply Direct Link To This Post Posted: 01 Aug 15 at 07:45
This looks the nuts mate.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote surf dude Quote  Post ReplyReply Direct Link To This Post Posted: 01 Aug 15 at 07:49
Originally posted by donecan donecan wrote:

This looks the nuts mate.


thanks pal, I'm pretty happy with it so far.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote surf dude Quote  Post ReplyReply Direct Link To This Post Posted: 26 Aug 15 at 21:27
Well, it's finished! But just so you don't miss anything......

Still plugging away, painted this,



And fitted it here



New bulbs and light fittings for the number plate lights, ordered new pressed plates but they haven't arrived yet so just popped the old one in for now.

Then moved inside to tackle the headlining as I obviously need that all fitted before I can get a new windscreen fitted.



And made a start on glueing it in. Think it's taken alright, but will have to check when I get back up there.



Fitted the back wheels with new tyres, connected up the fuel filler cap and pipe work, what a pita, had to drop the tank again and reconnect a couple of pipes, talk about a complicated design. One of the breather pipes into the expansion tank snapped so I checked the tank into the corner. May just connect the pipes up and vent it to the atmosphere, it all seems a bit overkill to me! And fitted a new mirror (bought some cheap mk1 golf replicas but they don't fit, which is contrary to what I've been told!)



jobs left then;

Fit door seals to front and side door and lockers
Get reversing light, horn , LHS main beam and brake light to work properly
Fix heater controls
Refit interior plastics
Fit door panels in rear
Fix load bed
Fill coolant system and bleed
Charge battery (again)
Wire in second lighter socket under seat.
Get wind screen fitted
Fit rear window.

Then get it in for an MOT!!
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surf dude View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote surf dude Quote  Post ReplyReply Direct Link To This Post Posted: 26 Aug 15 at 21:40
Next part

Well, today was a big day. Windscreen fitter was due at 11, and the van was booked in for its MOT anytime after lunch! I still had plenty to do, so I got stuck into the load bed. The woods a bit bowed so I popped to B&Q first thing and picked up some u shaped diamond pattern steel (I think that's what's it called but my brain is mush!) and screwed it all down. Then I cut out an engine hatch and fitted that with some nice shiny hinges from the local boat shop. The rear window runner finally turned up, but the frame is still pretty jagged as I didn't get round to repairing it and it just wouldn't go in, so I got some 4mm Lexan and shaped a new window. Judicious application of sealant means it's probably never coming back out, so that will have to do.

Windscreen man finally turned up at 3, and popped the window in and then it was off for the MOT. The engine cut out about 5 times on the way (8 miles) but even after all that it only passed!!! Quick run home, sluice 5years of muck off of the roof and down to my local where East Coast Retros hold their monthly meet.



Looks pretty sweet even though I say so myself! Yes, I am very happy. Dropped it off back at the garage so they can look at the cutting out issue, think it is probably the fuel pump/fuel starvation so they'll look at that first. Fingers crossed I'll be in it at the Retro Rides Gathering at the weekend :D more pics to follow, but I didn't even take any today!!

Thanks for all the support, no way could I have done it without it.

Pete
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Post Options Post Options   Thanks (0) Thanks(0)   Quote surf dude Quote  Post ReplyReply Direct Link To This Post Posted: 26 Aug 15 at 22:09
Last one!

Well, if you were at The Gathering you may have seen this in the campsite, which obviously meant I made it! So, the cutting out problem was down to the pre filter that I'd been advised to fit before the pump was restricting the fuel flow, hence the cutting out. That done we were looking good. But then, a warning light.... Quick run through the self diagnostic and we have a dodgy knock sensor. Well, I didn't have the time to fix that so AA card in hand (actually, that's bull because I realised on Sunday that it was in fact in the drawer at home!) I set off to meet another RR'r en route to Shelsley 189 miles away......





The last one isn't my picture but damn, that paint looks good!! So we took it easy, 60 all the way and the van performed faultlessly. Arrived and got settled.



This is pretty much where it stayed because on Saturday afternoon turning the key resulted in a clunk, but no turnover. Bump start and down to the petrol station to fill up for the trip home. Thanks to the guys who gave me a bump!! Sadly the van stayed there for the Sunday as well, I did try to bump it from the top of the campsite but wet grass and wide tyres don't work! A push at the bottom gate on the broken Tarmac got it going but I figured I should leave it there and just drag myself over to the show instead. I was gutted to be honest, but at least we made it there (and back again) and she's now tucked up back in the workshop with a new starter motor waiting to be fitted. Thanks to Chris, Jaimie and Gio not only for the amazing food but also for acting as bump starters in our hour of need!

More to follow of course, but will be taking a bit of a break to sort out the Escort....
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