This is one of my first posts as VanRex. Some of you will know me as 71EJVan or GL1972 (Green German Look SuperBug with 2110 and 17s) in AussieVeeDubbers. That car was originally bought to do up for my daughter's first car but I got carried away. Well I have decided to honour my commitment to her so I will be changing it by installing steel wheels and a standard 1600 twin port motor (she'll have the coolest car in school!). The motor is currently up for sale in the AVD spare parts forum if anyone is interested in looking. The project I have decided to do for myself will be a 1971 Bay Panel Van with a Subaru EJ20T conversion (another one to the dark and wet side!), rear disc brake conversion and total sleeper look. I purchased the van and brought it home in late August. It is quite solid but needs some TLC. Here is an abbreviated story to get you all up to date. The idea of a van is to get to the beach without having to tie my boards on the roof and also have some go to raise some eyebrows at the lights..... Surf and Swoosh! The will be no metallic paint or plush interior going anywhere near this Van. Waterproof ply and carpet for lining. Straight, clean and don't attract attention. 22/08/2005 Finally got it home yesterday after a 215 klm round trip. Its quite solid and straight however there is some rust to fix in the front floor, under the battery and the left A pillar. Love the lowlight look. I must have been ok at tieing it on..never moved an inch. What everyone's garage should look like! 24/08/2005 Well I have a motor! EJ20T WRX with only 70,000Ks good compression on all 4 pots. Came with ECU, Loom and Intercooler. I may even hook up the AC at a later date. It arrives Saturday. Bodywork starts this weekend with the removal of all non paintable bits (lights indicators etc). Removed bumpers, grilles, lights, indicators. Pulled engine and fuel tank. Pulled back wiring (this will be shortened back to a junction point near the ECU and new loom for connection). Removed sound deadening in engine bay. 29/08/2005 Bringing the WRX motor home. Note the envious look on the bug parked behind the trailer! The old and the new! Fuel tank removed also, ready to start modifying to fit the EJ20T. (modifying sounds better than cutting). I looked up a ratio calculator and with the 215/45/17 wheels I was going to install it would be super fast in the lower gears but rev too high for my liking at 110/120 kmh. Works out a lot better with 60 series tyres (don't know how available they are in 17 inch though). Would be worth changing the R&P at a latter date. Changed my mind on all this and decided to look for a 091 box. Will also fit some 15 or 16 inch steel wheels also. 01/09/2005 Well I've got hold of a 091 gearbox. Exchange plus cash. Decided to go with a 200mm flywheel and buy a Kennedy off the shelf clutch 1700 or 2100lbs. I will stay with the old 002 belhousing and starter so that I can use the 200mm off the shelf clutch. This will also mean that I could throw this engine in a dub if I desire without too much cost. Made a list of all parts including steel and ally sheeting I will need to complete the job. Woah! lots of bits. I will post it here for criticism on the weekend. 02/09/2005 I'll try posting this long list. Still some things to add. 08/09/2005 Picked up the 091 gearbox a couple of days ago. On changing the bell housing I inspected the crown wheel. No real discernable wear marks on the teeth and very little play. Looks in good condition. My 002 was in good condition also, would have made a great addition to an offroader with big wheels. Picked up all the steel for the cross member, fuel tank enclosure and radiator mounts. Took a list down to Metalcorp which included all the small cut lengths, came to $86 cut (who would use a hacksaw for those prices!!) Also picked up a alloy core sealed unit radiator with twin thermatic fans for the right price. All the metal is now cut out of the back of the Kombi to fit the engine (most of the engine seal apron and fuel tank shelf is now gone. Cleaned and painted the area ready for installation. Engine is now cleaned ready for test fitting. 12/09/2005 Cleaned out the cargo area and found that the previous Signwritter owner was not too worried about spilling paint everywhere under the chipboard. She's had a hard life and has carried some serious weight over the years. Picked up a near new alluminium core radiator complete with fans for $180 shhhh it?s a Deawoo Leganza unit!. Steel to make the new engine cross member, radiator mounts and fuel tank, battery and ECU/wiring enclosure. I still have got to submit a drawing of the cross member to my Engineer for approval before starting to build it. Will be picking up new intake gaskets, exhaust gaskets, injector to manifold seals and rear main seal from Ryde Subaru this week. Easy guys to deal with. Want to make sure there is no air or oil leaks when I install this engine. Also as it is a MY95 engine the seals may have gone hard. Have to also go back to engine supplier to pick up the Mass Air Flow Sensor that was missing. Jeremy from Tweakit was apologetic and rang back with 30 minutes to say that he had it there. Will pick up a air to water intercooler and circulating pump this week from SSS Automotive. 12/09/2005 A man and his grinder! This is me building the enclosure and mounts for the fuel tank and battery relocation and ECU and wiring. The unit will be aluminium or tin lined and also have space for a surge tank, pumps and even a jack and wheel brace. This will get a lot of weight forward and lower. Should assist in the handling. 13/09/2005 The main cross member that mounts between the chassis rails and picks up the Subaru engine mounts and will also have a support attaching to the lower 4 gearbox bel housing bolts. Was going to make a brace between the shock mount towers above the bel housing and create a tranny strap but this would foul the intercooler 27/09/2005 I finally got approval from my engineer for the cross member design and the adaptor kit turned up. The main framework for the tank enclosure is mostly made. Cut out for the engine hatch (big access!). Fitted the adaptor plate after a small amount of trimming and mated the gearbox. Fitted the old front mount to the 091 box and trimmed the studs as they fouled the torsion housing. Sat the engine/box in place and bolted up the front mount. Chocked the back for level and centre (checked this many times). On the weekend I made a big timber adjustable cross member. Set it in place and set angles whilst checking for clearance. Transferred these angles and all my other measurements to the concrete floor. The next job was to cut all the steel to match the angles drawn and started welding. After a couple of test fits the cross member is almost complete. Here is some pictures of the progress. Motor and box in place with front mount bolted up. Plenty of room in there without the tank. Another view showing intercooler clearance and space around engine. Fuel tank framework almost complete. Just need to weld in tank and battery supports. Dummy timber adjustable cross member used to work out angles. Took an extra day off for the long weekend intending to put some serious hours in on the van. Fortunately (or unfortunately) got some surfing in but didn't get everything finished. The cross member is now complete and the radiator mount is halfway there. Here is the completed cross member. It picks up the existing WRX engine mounts and also has a frame to connect to the 4 bottom bel housing to gearbox bolts via 2 rubber mounts. The tabs on the sides and the 25x25mm sections will bolt up to the original cross member hangers at the back of the engine bay. This will assist in reducing any twist at the bottom of the frame under acceleration. You can also see in the picture the transferred measurements on the floor. Here is the cross member plans for those interested in welding and grinding until they hate Tim The Toolman Taylor. The cross member is fitted in front of the tappet covers by 30mm. The width may vary a little between chassis rails. 01/12/2005 Here is a pic of the completed fuel tank, battery, electrics, fuel pumps, storage housing. The tank will sit on timber mounts on the two rails in the centre and be held down by steel straps (I'm re-using the old ones). The fuel tank area will be sheeted in 0.4mm steel and be sealed with both up and down ventilation to the outside (40mm pipe). the rest will be sheeted in ply and be trimmed in waterproof carpet. There will be 4 accessible enclosures. 2 for wiring and electronics, 1 for battery (you can see the frame on the lower right hand side) and 1 for tool storage (might put a second battery in here). The wiring harness in pretty much complete and in. I'm going to re-use the fuse blocks and relays from the original car. Going to feed the front of the van from this. I have identified all of the AC wiring and left it in the loom as I will AC the van at a latter date. All I have to do is take a feed to the front to pick up the original fuse box, have the ignition switch control a relay at the back for the starter (40Amp) and rerun the rear lights. The looms took 4 nights and one day to identify, rehash, shorten, remove unused, and recover. After much measuring cutting welding and grinding the radiator mount is complete. Here is three pics of the completed mount. The last one is a test fit under the van chassis. I will make some modifications the rear of frame to raise it a little. The scoop will be sheeted in 0.4mm and there will sheeting in front of the scoop under the floor to smooth the airflow out a little.