My VERY RUSTY VW T25 Camper Van Project

An area of the forum dedicated to the other marques and models sat on your driveway (please post only one thread per car)
User avatar
Robsey
Club Admin
Posts: 10664
Joined: Fri Dec 12, 2008 1:42 pm
Location: East Manchester

Re: My VERY RUSTY VW T25 Camper Van Project

Post by Robsey »

I tried to do some work on the engine today.
My first job was to drain the oil from the sump.

Seized solid, and the bolt head rounded off even though I used a 6-sided socket.
Bugger.

I took off the thermostat housing, to be stripped and prepared for the rebuild.
I am only re-using the coolant sensor.
I have a new stat and housing in my desk draw at work.

I was going to swap out the oil pump, thinking that this would allow the oil to drain.
The rotors came out, but the pump body was stuck fast.

Final task was to see how easy the exhaust bolts will undo. There are about a dozen of them in all, due to each combustion chamber having an exit pipe of it's own. Pipework wraps around the block like a 20ft long python.
The bolts (13mm spanner) are notorious for seizing and snapping.
Amazingly all bolts that I accessed were reasonably willing to be undone.
The only hiccup being that one bolt head was under-sized.
12mm socket instead of 13mm.
But thankfully it was not seized.

As usual the van got the better of me today, with little getting done overall,
even though it was the engine today that was fighting me all the way.

-------------------------------

I did try stripping the near side door, but little got done due to a seized screw in the check strap assembly, and
the thought that the glass is safer in the door, than stored loose.

I am awaiting the arrival of a battery drill, before I start to drill out rusted self tappers... and now the sump plug. :roll:
User avatar
Robsey
Club Admin
Posts: 10664
Joined: Fri Dec 12, 2008 1:42 pm
Location: East Manchester

Re: My VERY RUSTY VW T25 Camper Van Project

Post by Robsey »

New sump plug has arrived along with a separate sealing washer. (?)

Still awaiting the arrival of the cordless drill, before I can drill out all the corroded self-tappers.

UPDATE - 2/8/19 pm - Cordless drill received.
Time to rock and roll :D
Also have a whole rake of tools to strip the old bits off...
Stainless steel drill bits,
Full pack of screw and stud extractors,
Two big tins of plus gas,
And face-drive / contact sockets for the win.
User avatar
Robsey
Club Admin
Posts: 10664
Joined: Fri Dec 12, 2008 1:42 pm
Location: East Manchester

Re: My VERY RUSTY VW T25 Camper Van Project

Post by Robsey »

Another couple of hours in the unit gave a small, very slow amount of progress.

With my new-to-me DeWalt drill and some stainless steel drill bits, it was time to drill off some of those rusty screw heads.

First job was to remove one very rusty self tapper from the nearside front indicator.
The indicator is covered in over-spray, so will be cleaned if possible, otherwise it will be bin fodder.

One hole left by the removed indicator.
This is all just scabby surface rust... quite solid really.

Image

Then three screws from underneath the van to extract the screen washer bottle.

Amazingly, it seems like VW used nothing but self-tapping screws and J nuts to hold everything onto the body shell.

So one washer bottle, complete with 28 year old washer fluid.

Image

And the void left behind.

Image

Next task was the air vent on the near-side upper rear corner.
Again two very rusty self tappers.
Despite being quite old plastic, I managed not to trash the vent.

In this instance, plastic inserts were used in the vent mounting holes. - Not J nuts for a change.

Image

Last job of the evening, was to attempt to remove the sliding door middle track-cover.

A lot of brute force and ignorance was required to get the panel off, because my super tough drill bits were simply not able to drill out the two screws holding the cover on.

Revealing a seized up slider / runner arm,

Image

And a slider rail that has totally disintegrated.

The rail cover was virtually the only thing holding the cargo door in place. Stopping it from falling off the van.

Image

The remnants will need to be chiselled off to make way for a new runner guide-rail.

It is amazing how quickly 11pm arrives.
Time for home.

But not before I sweep up the usual pile of rust that rains down off the van when I work on it.
Tools packed, and Troy's unit left as tidy as I found it when I arrived.

He was there, but I made a point not to distract him.... yet.
User avatar
Mk3alan
Registered user
Posts: 637
Joined: Sun Mar 09, 2014 8:40 pm

Re: My VERY RUSTY VW T25 Camper Van Project

Post by Mk3alan »

Might seem like slow progress - but at least it's progress!

Alan
User avatar
Robsey
Club Admin
Posts: 10664
Joined: Fri Dec 12, 2008 1:42 pm
Location: East Manchester

Re: My VERY RUSTY VW T25 Camper Van Project

Post by Robsey »

Indeed it is...
Slowly slowly, catchy monkey as they say.

I was a little confused by the single green wire in a black sheath in the image of the hole left by the removal of the rear vent.

It was not connected to anything inside the inner wing.
And I am sure the connecting block is not an original VW fitment from 1982.

I think it is the rear-hatch trigger-wire to the the old Cobra alarm that was still fitted when I started this project eight years ago.

Still a huge amount to strip off before proper work begins.
cavalier1990
Registered user
Posts: 1465
Joined: Wed Jun 29, 2011 9:15 pm
Location: Paisley, Scotland

Re: My VERY RUSTY VW T25 Camper Van Project

Post by cavalier1990 »

Robsey

Looks like you're getting in amongst in there, quite a shocker with that door, ready to fall off. I suppose there was no danger as you had it of road anyway, although falling off onto your head wouldn't have been funny at all. I didn't read whole thread yet but have you got panels and stuff for it now/know what you need roughly?

Cheers

Andrew
User avatar
Robsey
Club Admin
Posts: 10664
Joined: Fri Dec 12, 2008 1:42 pm
Location: East Manchester

Re: My VERY RUSTY VW T25 Camper Van Project

Post by Robsey »

I anticipate a need for at least a dozen or so big panels.

At anywhere between £1000 and £2100, dependent upon what can be saved and which supplier I use.

My worry is that rear-runner rail.
Until recently, this came as part of a side skin.
Now the skin comes without it.
So the hunt is on to find a runner or a skin with the runner fitted (old stock).

I am only doing a few hours per month, so not going to get anywhere fast...
But hey ho, all in good time.

Plenty of other stuff to do, such as rebuild all my switch-gear onto the EPAS steering collumn.

Strip and clean various parts removed from the van already.
All stuff that I can do whilst my bank account recovers from being battered by the needy Cavalier.
3cav3
Registered user
Posts: 1447
Joined: Sun May 22, 2016 6:07 pm

Re: My VERY RUSTY VW T25 Camper Van Project

Post by 3cav3 »

If time is on your side, I've found before that if you look hard enough, almost anything can be found. One of my other interests is old Howard rotavator s ( see my website if you're interested http://www.howardgem.webs.com doesn't work very well on mobiles for some reason) and for the one machine I spent 8 years looking for a specific gearbox part, hopefully it won't take you that long to find a runner but I'm sure one is out there.
User avatar
Robsey
Club Admin
Posts: 10664
Joined: Fri Dec 12, 2008 1:42 pm
Location: East Manchester

Re: My VERY RUSTY VW T25 Camper Van Project

Post by Robsey »

Indeed, I have spent years looking for Cavalier parts.

And Kenwood System 21 components for the wife.

Got there on both counts in the end.

Although I am paying storage, I am in no rush to get the van finished tomorrow.

I have got a whole year's worth of weekend jobs to do, including -
designing the interior,
tidying modifying the wiring looms,
Completely redesign / rebuild the instruments and dash panel.

And most of all - learn a whole new approach to vehicle construction and wiring methods.
Volkswagen are truly a completely different kettle of fish to any Vauxhall that I have worked on.
Some of it is very clever...some is down-right weird.

The oddest being - having the brake fluid reservoir at the top of the dash, behind the instrument cluster...under the cluster cover.

Image
(Photo taken from Rotbox Restorations).

Don't even dare to spill any brake fluid :shock:

Interesting website by the way.
Truly a chap of diverse interests.
:D
cavalier1990
Registered user
Posts: 1465
Joined: Wed Jun 29, 2011 9:15 pm
Location: Paisley, Scotland

Re: My VERY RUSTY VW T25 Camper Van Project

Post by cavalier1990 »

Robsey

When you say design the interior are you going to customise it to your own liking, maybe make it a wee home from home? Go for trips to the lakes? :) I take it yours never had side windows are you fitting them as well?

When you mentioned that brake reservoir filler on top of dash that twigged my memory I've seen something similar like that when I was in the trade, it might even have been a transporter I seen it, can't think of any other that had filler like that.
User avatar
Robsey
Club Admin
Posts: 10664
Joined: Fri Dec 12, 2008 1:42 pm
Location: East Manchester

Re: My VERY RUSTY VW T25 Camper Van Project

Post by Robsey »

I think that is the American version, with a level sender on top.

The UK ones are a plain white cap with no sender.
They rely on a pressure switch on the master cylinder to show that "oil must be there, if there is pressure to operate the switch"

There are lots of van interior makers and suppliers.
But.
The wife wants it how her dad had it in the 80's.
So benches with cupboard storage inside like the really old caravans used to have.
Then seat and back cushions for comfort.

The only upgrade will be a porta-potti or caravan loo built into a "buddy seat", so that the wife does not have to look for a services if she needs to go...
User avatar
Robsey
Club Admin
Posts: 10664
Joined: Fri Dec 12, 2008 1:42 pm
Location: East Manchester

Re: My VERY RUSTY VW T25 Camper Van Project

Post by Robsey »

This may all still change, we know how readily women change their minds.

At the moment, she does not want a full camper interior,
But she wants a gas hob for cooking and a loo....

As for the van,
Yes it started life as a standard van with windows only in the cab, and the tail gate.

I think the father-in-law had 4 windows fitted - two per side, for light, and a very basic box seat along the driver's side and a box seat across the van immediately in front of where the floor rises over the rear-mounted engine.

From how it is described, the bench / box seats are extended out into a big bed by sliding out wooden slats along two rails, and then the seat and back cushions are positioned to create one big bed.

I recall this being how our long since scrapped 1977 ABI Ace Globetrotter caravan front bed-area was created.
Back in the day - lol

(That was another "vehicle" that I restored in 1996).

Until the wife discovered expensive far flung holidays in the Indian Ocean in 2005. :wall
3cav3
Registered user
Posts: 1447
Joined: Sun May 22, 2016 6:07 pm

Re: My VERY RUSTY VW T25 Camper Van Project

Post by 3cav3 »

Robsey wrote:Indeed, I have spent years looking for Cavalier parts.

And Kenwood System 21 components for the wife.

Got there on both counts in the end.

Although I am paying storage, I am in no rush to get the van finished tomorrow.

I have got a whole year's worth of weekend jobs to do, including -
designing the interior,
tidying modifying the wiring looms,
Completely redesign / rebuild the instruments and dash panel.

And most of all - learn a whole new approach to vehicle construction and wiring methods.
Volkswagen are truly a completely different kettle of fish to any Vauxhall that I have worked on.
Some of it is very clever...some is down-right weird.

The oddest being - having the brake fluid reservoir at the top of the dash, behind the instrument cluster...under the cluster cover.

[ Image ]
(Photo taken from Rotbox Restorations).

Don't even dare to spill any brake fluid :shock:

Interesting website by the way.
Truly a chap of diverse interests.
:D
Our 2004 Nissan Cabstar has a brake fluid reservoir in a similar place but access is bad as there's just a little hole in the dashboard. Made a hell of a mess when the lad at work wound the calipers back in to change the pads as it was already above the max line before he started.
User avatar
Robsey
Club Admin
Posts: 10664
Joined: Fri Dec 12, 2008 1:42 pm
Location: East Manchester

Re: My VERY RUSTY VW T25 Camper Van Project

Post by Robsey »

For that reason, I always loosen the calliper nipple when winding / pushing the pads back.

It is possible to have a spanner on the nipple with one hand,
And operate a lever or wind-back tool with the other.

My brake and clutch hydraulic pipework and fluid is so old, it will all need to be purged, cleaned, replaced where necessary and replenished.

I will probably do all of that before refitting the main bulk of the dash and steering collumn.
Just for better access.

BUT - That is way off into the future.
Finances and time mean that this is going to be a "slow burner" of a restoration.
3cav3
Registered user
Posts: 1447
Joined: Sun May 22, 2016 6:07 pm

Re: My VERY RUSTY VW T25 Camper Van Project

Post by 3cav3 »

Robsey wrote:For that reason, I always loosen the calliper nipple when winding / pushing the pads back.

It is possible to have a spanner on the nipple with one hand,
And operate a lever or wind-back tool with the other.
A spanner is the word we use to describe him, lol. He's not the brain of Britain.
User avatar
Robsey
Club Admin
Posts: 10664
Joined: Fri Dec 12, 2008 1:42 pm
Location: East Manchester

Re: My VERY RUSTY VW T25 Camper Van Project

Post by Robsey »

Totally at odds with the van, the father in law had fitted some natty stainless steel wheel covers / hub caps.

Image

I knew that they were not VW parts. They are always the "moon" style caps as used on the air-cooled Beetles.

A couple of months ago, I thought that I had finally sussed out the origin of the hub caps.

They looked a lot like SunLiner trims fitted to a 1967 Ford Galaxie 500.

Image

They are also similar to Mk1 Ford Transit trims too.

Anyway whilst searching for a totally different topic on a classic car magazine website, I finally saw the correct caps.

Amazingly, they look a lot more like they are off a Rover P6 circa 1973-ish.

Image

Image

Although not VW original parts, they are the parts fitted to the van in its hey day in the very late 80s.
So I am tempted to polish them and re-fit them at the completion stage.
3cav3
Registered user
Posts: 1447
Joined: Sun May 22, 2016 6:07 pm

Re: My VERY RUSTY VW T25 Camper Van Project

Post by 3cav3 »

I definitely would fit them. Even if a part isn't original, if it's spent most of its life on a vehicle then it deserves to stay. I've never really gone in for rivet counting anyway.
iangsi
Club Admin
Posts: 1714
Joined: Tue Jan 19, 2010 4:58 pm
Location: Bromley, Kent.

Re: My VERY RUSTY VW T25 Camper Van Project

Post by iangsi »

Put VW badges on them no one will ever know.
User avatar
Robsey
Club Admin
Posts: 10664
Joined: Fri Dec 12, 2008 1:42 pm
Location: East Manchester

Re: My VERY RUSTY VW T25 Camper Van Project

Post by Robsey »

3cav3 wrote:I definitely would fit them. Even if a part isn't original, if it's spent most of its life on a vehicle then it deserves to stay.
I do sort of like them, and I am keeping as much as possible to the originality of the memories of the van, not to the factory specification.

After all, it is a homage to her late dad Fred and their family holidays.
iangsi wrote:Put VW badges on them no one will ever know.
They need badges anyway...
But oddly enough, I am not sure if I want VW badges on them.

Do you think anyone would notice if I put griffin badges on?
Only joking, of course... :lol:

More thought required... :scratch
3cav3
Registered user
Posts: 1447
Joined: Sun May 22, 2016 6:07 pm

Re: My VERY RUSTY VW T25 Camper Van Project

Post by 3cav3 »

Robsey wrote:Totally at odds with the van, the father in law had fitted some natty stainless steel wheel covers / hub caps.

[ Image ]

I knew that they were not VW parts. They are always the "moon" style caps as used on the air-cooled Beetles.

A couple of months ago, I thought that I had finally sussed out the origin of the hub caps.

They looked a lot like SunLiner trims fitted to a 1967 Ford Galaxie 500.

[ Image ]

They are also similar to Mk1 Ford Transit trims too.

Anyway whilst searching for a totally different topic on a classic car magazine website, I finally saw the correct caps.

Amazingly, they look a lot more like they are off a Rover P6 circa 1973-ish.

[ Image ]

[ Image ]

Although not VW original parts, they are the parts fitted to the van in its hey day in the very late 80s.
So I am tempted to polish them and re-fit them at the completion stage.
I knew I'd seen these hub caps fitted to another VW camper, somewhere. Last night watching some old episodes of series 2 Auf Weidersen Pet, on Denis's van there was a set of these fitted, so maybe a common mod?
User avatar
Robsey
Club Admin
Posts: 10664
Joined: Fri Dec 12, 2008 1:42 pm
Location: East Manchester

Re: My VERY RUSTY VW T25 Camper Van Project

Post by Robsey »

Well would you believe it.
He isn't wrong.

Image

Fitted to the 2nd generation camper.
Type 2 - T2. (Bay Window).
Definite 70s colour scheme.
1972 van, not been taxed since 1986 :(
3cav3
Registered user
Posts: 1447
Joined: Sun May 22, 2016 6:07 pm

Re: My VERY RUSTY VW T25 Camper Van Project

Post by 3cav3 »

I think 1986 was when this series first aired, so hopefully somebody has stored it away for preservation. In my opinion series 2 was definitely the best one, such a shame Gary Holton died so unnecessarily before filming finished.
User avatar
Robsey
Club Admin
Posts: 10664
Joined: Fri Dec 12, 2008 1:42 pm
Location: East Manchester

Re: My VERY RUSTY VW T25 Camper Van Project

Post by Robsey »

According to your date-line, he had died a couple of years before the series was aired.
(Depending how accurate Wikipedia is).

------------------------------

In a twist of fate, to recoup some desperately needed funds, I am planning to sell some of the engine upgrade parts.

And rebuild / recomission the original engine and feeble carburettor.

The 2.1 litre refurbished engine,
complete new stainless exhaust and mounts.
full fuel injector control loom and induction assembly,
should fetch in over £1000 between them.
3cav3
Registered user
Posts: 1447
Joined: Sun May 22, 2016 6:07 pm

Re: My VERY RUSTY VW T25 Camper Van Project

Post by 3cav3 »

Wikipedia says he died in October 1985, if you watch quite a few of the later scenes he's always in the other room or an obvious body double is used on long distance shots. Such a needless waste of anybody's life wether theyre famous or not.
So would fit in with early 1986 transmission.

You've picked a bad time to sell the engine, since Mondays doom and gloom it's like somebody flicked a switch and everybody has stopped buying everything accept tins and bog roll.

On a more positive note though at least the camper will now stay original, however there's nothing wrong with tasteful mods.
Look forward to seeing the work progress and hopefully it ends up as nice as your Cavalier.
User avatar
Robsey
Club Admin
Posts: 10664
Joined: Fri Dec 12, 2008 1:42 pm
Location: East Manchester

Re: My VERY RUSTY VW T25 Camper Van Project

Post by Robsey »

The mods were really to double horse power, without increasing mpg.

In fact the proposed engine was more efficient and produced lower emissions.

And much more reliability of a simple fuel injection control system over a very crude carburettor set-up.

We shall see...

Update - 20/3/2020.
According to the boss / missus / swmbo...
I am not allowed to sell any proposed van parts. :scratch
Post Reply