late bay 1.9 td/tdi twin slider project

13 window deluxe

i've had my new little ebay bay window project camper about 3 or 4 weeks now and i thought i best let you in on my progress so far.

here the van when i first got it back to the garage a sorry sight gone as many good vans before it with the old engine fire!

this is what greated me when i opened the engine lid for the first time

first things first get rid of that old burned lawn mower motor

while the engine was out i thought remove the rotten back panel and make it removeable with a spare early bay one i had kicking about the garage

i then looked at what could be done with a engine inspection hatch i was going to use another t25 hatch and boot floor but decided to neatly cut out old floor and refit onto a custom frame so when finished and closed the hatch will be almost invisable as all pressing will line up so out came the plasma cutter and the tape measure (measure twice cut once)

then i got a little bored with the engine one afternoon the surface rust on rear end had to go so out came the wire brush on the grinder

i then started cleaning the engine bay up for the new engine and found a few little supprises under the old burned sealer and wax!!!

so a bit of welding later and were back on track and then the same on the other side of the engine bay when that was cleaned up

now it's time to start on the engine side of things i decided to fit the engine at 50 degree's using as many factory t25 bits as i could to save the time and hastle of sorting a good adaptor plate from the states and to save some cash, with the bay being a 091/002 box from the factory the original bellhousing is removable and will interchange with the t25 diesel bell housing the input shaft will have to be cut 10mm or swapped for the diesel one if you using a type4 engined box but a type1 engined box will not need cutting as they are already shorter.
standard top mounted late bay bell housing

bellhousing removed in-situ

diesel bellhousing fitted to original gearbox

gearbox lifted to original hight (note cross member cutout to clear starter motor housing on bellhousing)

i now fitted a 4cylinder engine bottom eng this is just for mocking up the mountings etc and is lighter to work with than a fully built 1.9 diesel

next up t25 engine mounting brackets and rubber mounts

time for a 1.6td t25 jx sump

i now started looking at make a support bar for the engine in the end i decided to use the original bay engine mounting bar holes and to make a engine crossmember to go underneathe supporting the engine and doubleing up as a sump gaurd for the fragile cast alloy sump

the bar painted

next thing back to the hatch fitted the inner angle frame first then the hatch frame afterward still need finishing but looks like it will work ok

rolled the van over to repair a few more spots of tinworm while it was in bits as the test station will be its maiden voyege so it needs to be solid

a week later welding all done and the lawn mower bits chopped off the bottom i stone chipped the underneath then fitted the main coolant pipes

shes back on her wheels since sunday and ive got a disco radiator so i've been playing with that going for a alex type spare wheel rad set up as the van is very low and under floor rads would be a no-no for damage and getting airflow under van
_________________
1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,

previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi

13 window deluxe · Posted: Mon Jul 21, 2008 10:29 pm Post subject:

had to try wheels on at weekend even though my adaptor wont be here till tuesday and they looked sound

i will keep you updated on progress got some custom problem solving bits to pick up from machine shop tomorrow
_________________
1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,

previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi

ElusiveStranger · Posted: Mon Jul 21, 2008 10:36 pm Post subject:

Nice going!
I wish my roof was as good as yours appears! I'd settle for a scorched backside.
_________________
The advice you receive on here is worth the paper it's written on.
Your experiences are worth shed loads to others, including the f'ups - live and learn.
Wouldn't YOU rather learn by someone else's mistakes? So would they.

'78 Bay, 2 litre 091 box, EJ20 NA & the ashtray's on the 'right' side.
I don't lean forward for hills any more Grin

Bugger, missed out on "Live fast, die young"

13 window deluxe · Posted: Mon Jul 21, 2008 10:48 pm Post subject:

thats the only panel without filler(fingers crossed as i write that!!!) not to bad really for a rhd uk van will look ok with a splash of paint and my new wheels
_________________
1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,

previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi

13 window deluxe · Posted: Mon Jul 21, 2008 10:53 pm Post subject:

when i rolled the van over to weld it i checked the gearbox code before i started looking for a 2000 box as it was originaly a 1600 twin port van and found the gearbox was a late 2000 cp code box that had had the input shaft shortened to suit the type 1 motor result

_________________
1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,

previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi

andewilson · Posted: Tue Jul 22, 2008 11:07 am Post subject:

those coolant pipes seem to be going all the way to the front. where are you planning to fit the rads mate?
_________________
most bad experiences ive had included cars that werent german. never again

13 window deluxe · Posted: Tue Jul 22, 2008 7:17 pm Post subject:

going to be a fake spare wheel unit on front panel with a landy disco 300tdi rad and 15" suction fan. vans a bit to low for rads underneath
_________________
1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,

previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi

andewilson · Posted: Tue Jul 22, 2008 8:40 pm Post subject:

thats a bit of a worry, i was planning on fitting two rads in the centre and running my van v low. i was however going to fit an adjustable air scoop controled by the unused fresh air levers on my dash. pulled up and out of the way for slow cruising over speed bumps etc. then dropped down for maximum airflow when im givin it the beans
_________________
most bad experiences ive had included cars that werent german. never again

13 window deluxe · Posted: Tue Jul 22, 2008 10:16 pm Post subject:

that would be ok if the rads were level with the chassis rails but i wouldnt want them to hang down any as the front beam has worn flat to the axle tube nearly its that low! you would need very thin fans and a thin box over the top of the rads to get the rad setup as thick as the chassis rails. im going to change the radiator box and rads on the split over winter when i fit the tdi engine i've got 4 nice thin fans just need to make a box up to suit when the vans on its side

£5 each so i bought 4 that 2 side by side for each rad there 12" diameter and 2" thick hows that sound? before you ask there off a landrover disco1 or rangerover classic with air con and there blow through as there mounted in front of the aircon rad in a landy.
the spare wheel rad might only be a temporary thing to get the bay on the road while the split is of the road i was thinking about a rad inside the front panel and i bought a extra upper vent grill to weld into the front panel above the bumper from bvf as i prefer to see bays without a spare on the front, i will see how i get on with it and how much time the split eats up over winter the good thing about the spare wheel idea is it can be reversed easily by removing a few brackets
_________________
1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,

previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi

13 window deluxe · Posted: Wed Jul 23, 2008 9:38 pm Post subject:

i collected the coolant outlet elbow i have had made for the heater on my bay project today from my local macine shop i designed it to fit between the head and petrol tank shelf without fouling as there is only 25mm to play with

and my porsche adaptors are finished just need to press in the studs tomorrow had them made hub centric & stud and nut rather than just bolts as it easyier to get wheels on

_________________
1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,

previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi

andewilson · Posted: Wed Jul 23, 2008 10:13 pm Post subject:

how much did your man with the lathe charge for the adapters? im am after a set and some other machining
_________________
most bad experiences ive had included cars that werent german. never again

72panelvan · Posted: Wed Jul 23, 2008 10:13 pm Post subject: