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Feb 20, 2010 17:39:35 GMT
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About time for an update methinks ;D Sorry it´s taken so long but my back has been slowing me down and after landing in hospital for a couple of days i´ve been taking it easy. Before I get stuck in i´d just like to thank everyone for voting the van "most anticipated 2010" we were a bit concerned how the build would go down as a lot of people knew the van before we started cutting it up but I guess our doubts were unfounded. ;D Well with the Merc engine hovering in thin air, the next job up was to line everything up and get some engine mounts made. I took loads of measurements but still ended up lining it up by eye  The hole in the back has helped a lot, I should have done this a couple of years ago when I squeezed the 24V in but we live and learn and this conversion will be spot on first time...  I mocked up the radiator first to make sure I got the clearance from the fan right..  I chopped out the front beam of the W123 to have a play with it..   only to bin it all after a bit of measuring as it wasn´t going to fit. On the passenger side I used the original Merc mount on the engine and modified the old 24V frame mount to fit..  this wasn´t possible on the drivers side so had to build it from scratch  probably a bit "over dimensioned" but better safe than sorry.  With the engine mounts sorted next up was the gearbox mount. Using the original Mercedes rubber bit I made up a bit of box section...  and welded it inbetween the chasssis rails and with a bit more box section added the gearbox mount was sorted too   Next up: Propshaft and inlet manifold woes.. |
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Last Edit: Apr 15, 2010 9:35:11 GMT by Oldbus
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Feb 20, 2010 19:59:36 GMT
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Whooop !!
Oldbus back on track.
I have been busy around the house too, and it does feel great getting on with something, anything.
Look forward to updates as they unfold.
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Feb 20, 2010 20:46:06 GMT
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You make it look so easy.Really looks good.
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Peace,Max signature height = 80px
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stevea
Part of things
Posts: 281
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Feb 20, 2010 22:52:03 GMT
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I'm loving the build, but I'm not sure about the gearbox rubber mount. The mount looks more to me like it should be in compression rather than tension.
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cool did't take long to get that in and mounted  |
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I'm loving the build, but I'm not sure about the gearbox rubber mount. The mount looks more to me like it should be in compression rather than tension. Thanks for that mate, hadn´t thought of that....looks like plan B then ;D |
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Feb 21, 2010 18:11:32 GMT
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Plan B it is then... (cheers Steve  ) spent today making a new gearbox mount. I think a bit of W123 front axle should be up to the job...  Luckily it´s weldable...  so with a bit of box section...   and a bit of anglegrinding..  i came up with this contraption, which is definetly better than the old one  |
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Feb 21, 2010 20:16:42 GMT
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doing Rians bus, I can truly appreciate just how difficult these things are to do engine conversions on! but you make it look too bloody easy ;D ;D really great work mate I can see all the chassis work that went in to it in the first place now, makes me realise how lucky I am to be just doing a zetec |
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luckygti
Posted a lot
I need to try harder!
Posts: 4,912
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Feb 21, 2010 21:30:22 GMT
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Good to see you back on it Dave, on a roll now |
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10mpg
Club Retro Rides Member
Posts: 4,253
Club RR Member Number: 204
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Feb 21, 2010 23:23:44 GMT
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Great build i'll bet it took big cojones to slice that lovely van up..
One question though why do none of you hacksaws have blades??
is there a special (euro) german law disallowing more than one hacksaw per family?
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The Internet, like all tools, if used improperly, can make a complete bo**cks of even the simplest jobs...
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doing Rians bus, I can truly appreciate just how difficult these things are to do engine conversions on! but you make it look too bloody easy ;D ;D really great work mate I can see all the chassis work that went in to it in the first place now, makes me realise how lucky I am to be just doing a zetec You´re the only person I know that could write "just doing a Zetec" and mean it ;D Edd I know exactly how much work you´ve had to put into the conversion and I think we´re quits mate Good to see you back on it Dave, on a roll now Cheers Pete, getting there slowly Great build i'll bet it took big cojones to slice that lovely van up.. One question though why do none of you hacksaws have blades?? is there a special (euro) german law disallowing more than one hacksaw per family? It was John that had the balls of steel mate, it was his idea Not sure what you mean about the hacksaw though? Bringing us back up to date here´s - what i´ve been up to the last few weeks... With the engine mounts in place I could now get all the bits and bobs fitted.. The diesel filter needed moving so made up a bracket..  and moved it over a couple of inches still using the original hoses  The exhaust and inlet manifold are on the same side on the 240D and i´d removed them whilst fitting the engine as there was definately no room for them... ..but that´s what anglegrinders are for, a bit of modification to the bulkhead soon had that sorted.  ...the airfilter will be extended out towards the front of the van but this will do for now to get it up and running. Next up was to figure out a way of getting the engine to stop - now that might seem a bit daft but the diesel pump is operated on the same vacuum system that runs the central locking - and all that got binned along with the Merc... The pump has a manual cut off switch though so I bought a choke cable..  ...connected it up to the bulkhead...  .. I then drilled and tapped a hole in the cut off switch and using old bike brake handle bits connected the choke cable to the cut off switch.  I´ll have to block off all the old vacuum connectors but this should work quite nicely.(famous last words  The Merc diesels have a choke too - well actually it´s a tickover adjuster that can be set from the dash normally. This was easy to fit, you can see the switch here just above the cut off switch..  all you do is turn the switch a couple of times and it adjusts the pump linkage...  With the propshaft out of the way (half Ford - half Mercedes)  and the exhaust done too (Capri rear box, Merc middle box ...  my "to do" list is getting shorter ;D Hopefully I can get all the electrics sorted and have it running next weekend. |
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Last Edit: Feb 22, 2010 10:22:22 GMT by Oldbus
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mrj
Posted a lot
Posts: 1,662
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hey, it's getting forward here .... ;D I am really interested of the finished product; i recall having a similar engine in a 310 a couple of years ago, i remember it being very loud on longer trips, are you planning additional soundproofing or "it's just John" ? ;D
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- 1971 VW 1600 TL Fastback
- 1978 Passat GLS Variant
- 1980 Audi 100 5E
- 1981 VW aircooled panel van (sold)
- 1983 VW Jetta Mk.I
- 1984 VW Polo Coupé
- 1984 VW Passat hatchback
- 1987 VW Passat Variant
- 1987 VW Passat hatchback
- 1988 VW T25
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hey, it's getting forward here .... ;D I am really interested of the finished product; I recall having a similar engine in a 310 a couple of years ago, I remember it being very loud on longer trips, are you planning additional soundproofing or "it's just John" ? ;D It´s only John and that´s what I Pods are for..... No seriously Jürgen, i´ll be building a double bulkhead/ enginecover thingey to bring the noise levels down - but these were never quiet autobahn cruisers |
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doing Rians bus, I can truly appreciate just how difficult these things are to do engine conversions on! but you make it look too bloody easy ;D ;D really great work mate I can see all the chassis work that went in to it in the first place now, makes me realise how lucky I am to be just doing a zetec You guys would make walking on water look easy too Edd, I am so thankfull to have you and Dave on the case. Looking good Dave, catch you on the phone later. |
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DutyFreeSaviour
Europe
Back For More heartbreak and disappointment.....
Posts: 2,944
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Feb 22, 2010 11:56:43 GMT
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Brilliant stuff Dave, thanks a billion-zillion etc... (you get the picture) for the work you've put in. Can't say how much it's appreciated fella.
Don't sod your back up on my (or the bus') account though eh?
The GT6 is now 4 layers of croddy chassis 'repairs' lighter and will be taking shape asap. I WILL get it done in time mate - can't let the side down.
Anything you need - my fault etc... so just holler.
Thanks again......
John
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Back from the dead..... kind of
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Brilliant stuff Dave, thanks a billion-zillion etc... (you get the picture) for the work you've put in. Can't say how much it's appreciated fella. Don't sod your back up on my (or the bus') account though eh? The GT6 is now 4 layers of croddy chassis 'repairs' lighter and will be taking shape asap. I WILL get it done in time mate - can't let the side down. Anything you need - my fault etc... so just holler. Thanks again...... John Once the engine electrics are sorted i´ll be building the engine cowl etc and will need the winch...do you want me to get one? |
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Mar 10, 2010 16:38:33 GMT
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Good to catch up with this. It's looking nice |
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Mar 10, 2010 17:56:41 GMT
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ze talent is amazing ;D
edd youre nuts too
wasnt sure about rrg10 but gotta go just to see this the gt6 and the grizz bus in full effect
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Last Edit: Mar 10, 2010 18:11:23 GMT by hairnet
2001 HONDA CT110 (NOT RCV)
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Bit of an update necessary... Time to sort out the gearchange mechanism. I didn´t want to reuse the old van column change as although it looked good it wasn´t very safe as there was no mechanical barrier between drive and reverse (remember the episode with the garage wall a couple of years ago?) Well if it´s good enough for Mercedes then that´ll do me  I´ve made up some rods and connected the Mercedes gearchange directly to the gearbox - it took a while to get it all figured out but it works well and doesn´t look to ropey either. The bracket that holds the gearselector is just knocked up out of a bit of box section and placed as far to the left as possible so that the connecting rods pass the radiator and fuel pump.   One of the reasons the 24V blew up on me was it must have been running too warm. We knew it was warm in the cab but i hadn´t realised how hot until i had a look at the inner wings  The paint has been burned off by the heat of the exhaust manifold...ooops!  So took all that back to bare metal, still no signs of any rust, and so that it stays that way i primed and painted it in two pack and gave it all a dose of black wax.   I´d ordered some new carpet so with the gearchange sorted and test driven it was time to redo the cab floor.  Next job up was to tidy up all the electrics...  All the "new" diesel bits are not bodged into the dash to keep it clean (they´re in the bulkhead inbetween the drives legs)  ... the only exception is the glow relay light which doesn´t look too much out of place next to the light switch.  It´s all in and working now  This lot needs a new engine cover and a bit of tidying up, part of the cover frame will need to be very strong as i want to fit the winch in here somewhere with the cable going up through the "roof". Next jobs "to do" Finish off electrics Make engine cover and winch frame Fit new fuel lines and modify tank for diesel Renew brakes Test drive ;D I´ll get a video done at the weekend with it up and running but i really need to redo the front brakes as the wheelarches weren´t the only things i cooked on the last run with the 24V Getting there slowly cheers, Dave |
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Apr 15, 2010 10:00:21 GMT
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Nice going dave, looking good, one thing about vans is they tend to have more room underneath than cars do, so what you lose out on in the squashed engine bay you gain back by having an easy job getting a gearbox in. I must get a move on or i'll never catch up.  |
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Volvo back as my main squeeze, more boost and some interior goodies on the way.
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