bigt
Part of things
Posts: 86
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To keep the mojo alive I sometimes trial fitted more parts just to be sure I was still doing it right. The `ears` sticking up from the cab are trim still to be cut back. The GRP bed wing in place with a rear light held in place. Tailgate hung in place. Floor planks laid out and the nearside wheel arch cover in place. It is a unusual shape to add strength. Side view. The pick up is slightly longer than the car resulting in the wiring loom needing to be extended. My electrical skills being limited to `you can`t see it.....and it bites`. Due to the length of time between removing original lights and fitting replacements - I tagged everything at early stages of dismantling Closer view of the offside wheel arch cover which joins the bed side panels to the floor of the bed Both wheel arch covers in place. I built this on my drive way.....Not every day was a build day. More soon
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bigt
Part of things
Posts: 86
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Jun 12, 2023 19:50:40 GMT
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Wooden bracing in place. Below you can see some of the 5mm C channel under floor bracing. Various options for the bed floor. The kit has 3 aluminium ribbed planks for the floor. Some weld them in and do away with the spare wheel in its original home. I opted to weld the 3 planks together and cut them into 2 panels. The smaller panel behind the cab giving access to the top of the fuel tank and the larger panel at rear giving access to the spare wheel Access to fuel tank Access to the spare. I made one of the C channel braces removable to access the spare wheel and tools etc 4 tie down points made from 2 redundant rear door catches and another 2 from ebay Securing the wheel arch covers. When the cover is fitted as in picture you can not see the folded flange that is up against the bed side. All of these fixings are holding the bed side together with the wheel arch cover and when the GRP wing is fitted none of it is visible........
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braaap
Posted a lot
Posts: 2,597
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Jun 12, 2023 20:10:35 GMT
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Just found this thread after a random google.....Built mine a while ago and yes it has passed an IVA Only quoting You to have the finished car picture at hand for comparison. Great build and thanks for the effort to show us the how-to.
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bigt
Part of things
Posts: 86
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Jun 14, 2023 19:45:34 GMT
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One of the last major parts to fit....I left the rear cab window to last. It is a replacement for a Hilux. Heavy frame and sliding middle window. I made up a temp window to save any `accidents` The tailgate (supplied) is a copy of a Ford Explorer....made in Taiwan and not the best. The marks to the lower right are an attempt to weld up the holes for the Ford badge. Rear panel below is still being held on by Clecos. These turned out to be a good investment for holding panels together before the final fix You can see the panel for the fuel filler neck. Just cut to shape and fit the old filler flap. I did not connect the flap to the release in the cab as the cable route is not accessible when all the panels are fixed and I was not too keen on having a fuel tank I could not fill if the release failed. Used a lockable cap behind the flap By this stage it was looking like a pick up and time to contact the DVLA. I wrote and informed them the body style had changed..........in return they wanted before and after photos, receipts for parts purchased and what I had done with the removed parts. This took nearly 3 months...each time I filled in and returned the paperwork another form was sent. They were very keen to know where all the unused parts went - which in my case was the scrap yard as I could not give the rear doors, seats, boot lid, etc way. Finally a V5 arrived with body style as pick up, I was a little surprised...but they know what they are doing!!!!! Time for MOT...
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Last Edit: Jun 14, 2023 19:46:48 GMT by bigt
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braaap
Posted a lot
Posts: 2,597
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Jun 14, 2023 19:53:19 GMT
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Nice result so far. What are these rear lights from?
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bigt
Part of things
Posts: 86
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Jun 14, 2023 20:26:58 GMT
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Again Ford Explorer, they are copies, supplied with the kit
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Darkspeed
Club Retro Rides Member
Posts: 4,695
Club RR Member Number: 39
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Vw bora pickup kitDarkspeed
@darkspeed
Club Retro Rides Member 39
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Jun 14, 2023 21:01:29 GMT
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So it didn't pass a BIVA then - the DVLA just cocked up and changed the body style on the V5c?
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Last Edit: Jun 14, 2023 21:01:43 GMT by Darkspeed
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bigt
Part of things
Posts: 86
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So it didn't pass a BIVA then - the DVLA just cocked up and changed the body style on the V5c? You are spoiling the fun that is to come........
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Blimey, a fantastic build project and edge of the seat administrative drama - it's almost too much to bear!
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2005 Volvo C70 2.4T Convertible. 40k miles, FVSH, one prior owner. My toy. 2010 Mini JCW Convertible. Wife's toy. 1991 Yamaha FZR600, one of only 20 Kocinski edition models. MINI Cooper S Electric '3' - My daily scoot. Peugeot 2008 HDi120 - Dog van. Polestar 2 - Wife's daily. Dacia Jogger Extreme hybrid dog van replacement ordered, due Jan '24.
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Darkspeed
Club Retro Rides Member
Posts: 4,695
Club RR Member Number: 39
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Vw bora pickup kitDarkspeed
@darkspeed
Club Retro Rides Member 39
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So it didn't pass a BIVA then - the DVLA just cocked up and changed the body style on the V5c? You are spoiling the fun that is to come........ Ah just a teaser -- more interest and intrigue to follow.
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Paul
Posted a lot
Posts: 1,907
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So it didn't pass a BIVA then - the DVLA just cocked up and changed the body style on the V5c? I looked at doing a Beetle pickup using the same kit and got put off by the need for an IVA and probable Q plating...
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bigt
Part of things
Posts: 86
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Jun 15, 2023 15:45:49 GMT
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Jun 15, 2023 16:17:52 GMT
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Bravo on the colour choice Sir.
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2005 Volvo C70 2.4T Convertible. 40k miles, FVSH, one prior owner. My toy. 2010 Mini JCW Convertible. Wife's toy. 1991 Yamaha FZR600, one of only 20 Kocinski edition models. MINI Cooper S Electric '3' - My daily scoot. Peugeot 2008 HDi120 - Dog van. Polestar 2 - Wife's daily. Dacia Jogger Extreme hybrid dog van replacement ordered, due Jan '24.
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bigt
Part of things
Posts: 86
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Jun 16, 2023 16:36:55 GMT
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So as I said after 3 MOTs and over 2.5 years on the road I get the above letter. Not impressed was an under statement!!! Straight on the phone...The DVLA were very quick to point out I had done nothing wrong...the mistake was theirs!!!! but they refused to put that comment in writing. I had supplied all photos requested, all forms completed, all paperwork submitted but it was their mistake. It was rather ironic that the voiding letter was also signed by the same person who had issued the pick up V5. One thing that kept nagging was.....at the time the DVLA (and other Government departments) were taking industrial action, working from home, backlogs after COVID...yet they had time to `review their records`. It was a while before the re-registration section made contact (in fact all through this it was taking 2 weeks plus to get an answer to a letter). They sent a pile of forms (already submiited in the past!!!) issued a new VIN number and forms to apply for a IVA. I thought it would be useful to make contact with the IVA man (my local IVA centre was just 14 miles away) to ask for advice, etc. He turned out to be the most unhelpful person I have ever met, informed me he only worked 2 days a week and that my pick up would fail as I had cut the monocoque (I knew of a similar build that had passed SVA so I took his words with a pinch of salt!!!) While I was there he was failing a US import on its 2nd retest...the issue being colour...the car was wrapped lime green (is that a permanent change of colour???) ....under the `hood` the original colour was still showing....dark green!!!! I left them to argue it out. My IVA date came through, and was cancelled at very short notice, a new date was duly arranged. I arrived at the IVA centre in good time and awaited to be called into the building. On driving in he informs me `that`s going to fail...you have cut the monocoque and it is too noisy ( I had removed the rear of original exhaust due to rust and had a nice stainless replacement made up deleting the back box and making it slightly longer). So what happens at an IVA? ?? Basically a MOT that costs £450 is the short answer, the only things in addition to a MOT were a noise meter for the exhaust and each wheel was weighed. Bearing in mind VW had no doubt spent millions making sure the VW parts all legal, etc. With a 92% first time fail rate I was pretty certain he would find something wrong......and he did....failed on `Air bags not permitted in amateur built vehicles` and `rear window not correctly marked`. He had checked with his senior engineer re the air bags as VW fitted them 20 years ago...I had not touched them and had no idea if they worked. During the test he asked me if the airbags were fitted....had I said no he would of taken my word and passed it. TOO BLOODY HONEST. He also said if I presented the pick up again with the rear window removed he would pass it. So another 2 months pass before the retest (that`s another £90) and I am presented with a pass certificate. By this time I had studied the IVA manual - 323 pages - and found that the rear cab glass that had been failed was acceptable as it had a DOT number which matched an E number All I had to do now was send off another pile of paperwork to the DVLA (after having it MOTd first!!!) for registration and await my new reg number....
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Last Edit: Jun 16, 2023 16:41:28 GMT by bigt
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Jun 16, 2023 17:03:55 GMT
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FFS !!
Just to point out, the Like button was not a like in this case, but a nod at your dogged determination.
I like this build, and the resultant proportions work, as often they do not when going 4 door to 2 door.
Well done.
I would however love to squeeze the idiot who failed you and caused the havoc’s head in a vice and tighten it till it goes pop with a crunch.
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Jun 16, 2023 17:29:26 GMT
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Personally I'd make an official complaint to the powers-that-be about the rear glass failing when it shouldn't and I'll advised remarks about cutting the monocoque. The guy deserves a swift kick in the plums from his employer.
Brilliant project, even the paperwork side was interesting!
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2005 Volvo C70 2.4T Convertible. 40k miles, FVSH, one prior owner. My toy. 2010 Mini JCW Convertible. Wife's toy. 1991 Yamaha FZR600, one of only 20 Kocinski edition models. MINI Cooper S Electric '3' - My daily scoot. Peugeot 2008 HDi120 - Dog van. Polestar 2 - Wife's daily. Dacia Jogger Extreme hybrid dog van replacement ordered, due Jan '24.
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bigt
Part of things
Posts: 86
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Jun 16, 2023 17:41:13 GMT
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As you will see soon....I did make formal complaints to both the DVLA and DVSA based on my experiences
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Jun 16, 2023 18:21:18 GMT
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Oooh, you tease!!!!
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2005 Volvo C70 2.4T Convertible. 40k miles, FVSH, one prior owner. My toy. 2010 Mini JCW Convertible. Wife's toy. 1991 Yamaha FZR600, one of only 20 Kocinski edition models. MINI Cooper S Electric '3' - My daily scoot. Peugeot 2008 HDi120 - Dog van. Polestar 2 - Wife's daily. Dacia Jogger Extreme hybrid dog van replacement ordered, due Jan '24.
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bigt
Part of things
Posts: 86
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Jun 17, 2023 10:00:45 GMT
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So with passed IVA cert, MOT cert, Insurance cert and numerous other papers - all bundled off to the DVLA. One of the numerous documents I received from the DVLA was INF 26 `Guildlines on how you can register kit cars, etc, etc. This revealed with a cut or altered monocoque from an original vehicle and 2 original major components from the list of original monocoque, suspension, axles, transmission, steering and engine I could be issued with a age related plate. So to be on the safe side I included a letter explaining I retained all of the major components and should be issued with a age related plate. as you may recall the original letter from the DVLA stated a Q plate would be issued. After a couple of weeks a DVLA form V948 (Number plate authorisation certificate) arrives allowing me to go and get number plates made with my new age related plate!!!!!!! Also included was a receipt for registration fee and VEL showing a Q plate had been issued but was crossed out and age related plate written. The following day the V5 arrives showing I now own a KANGDA pick up.....another phone call to DVLA where the young woman is somewhat embarrassed to admit she has no idea where that idea came from, other than it can no longer be called a VW. We agree to call it a Smyth (maker of the kit). Another V5 is issued. I suspect KANGDA is either computer generated somehow or this is artifical intelligence at work. So finally I am back on the road.......and I write some letters.....
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Last Edit: Jun 17, 2023 10:10:10 GMT by Rich
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bigt
Part of things
Posts: 86
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Jun 19, 2023 16:12:45 GMT
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So I went from this.... .... to this. Now I am back on the road I write to the DVLA and DVSA outlining `my unhappiness` in the way each department went about their business. The DVSA quickly responded stating the air bag issue was because my pick up was now lighter and longer than VW intended and therefore may affect the operation of said air bags. Fair enough answer, but there was no indication 20 year old air bags would operate which ever vehicle they were fitted in. I gave them to my son in law who works at local police workshops and he fired them in a purpose build cage....they all went off as intended. On the subject of telling me what was wrong with the conversion before it had been examined...some customer facing training would not go amiss....and missing the DOT number on the failed re glass...human error. The DVSA letter was well written and the author had even taken time to find out I had passed the retest. On the other hand I had to write a further 2 times to the DVLA with the mention of a FOI request before I got a response. That turned out to be 2 pages of `civil service speak` which went round in circles and didn`t answer any of my complaint. I gave up taking it any further. Throughout this saga quickly discovered the DVLA and DVSA may have the same paymaster but they do not speak highly of each other and I doubt speak to each other. Both are mainly staffed by clerks who probably either walk to work or use a bus and have little or no interest in cars!!! I know of only 2 other Smyth conversions that have undergone SVA/IVA...the remainder`s owners deciding to leave as is...which is the builders/owners choice If any one reading this needs any more info re the Smyth conversion kits please feel free to message me
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