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The surf and swoosh project, 71 Lowlight Panel. The second coming.

Discussion in 'Resto Corner' started by VanRex, Dec 24, 2005.

  1. VanRex

    VanRex Member

    Messages:
    258
    Location:
    Central Coast NSW
    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.
    [​IMG]

    Its quite solid and straight however there is some rust to fix in the front floor, under the battery and the left A pillar.
    [​IMG]

    Love the lowlight look. I must have been ok at tieing it on..never moved an inch.
    [​IMG]

    What everyone's garage should look like!
    [​IMG]


    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!
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    The old and the new!
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    Fuel tank removed also, ready to start modifying to fit the EJ20T. (modifying sounds better than cutting).
    [​IMG]

    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.

    [​IMG]


    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.

    [​IMG]


    Picked up a near new alluminium core radiator complete with fans for $180 shhhh it?s a Deawoo Leganza unit!.
    [​IMG]


    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.
    [​IMG]

    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.
    [​IMG]

    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.
    [​IMG]

    Another view showing intercooler clearance and space around engine.
    [​IMG]

    Fuel tank framework almost complete. Just need to weld in tank and battery supports.
    [​IMG]

    Dummy timber adjustable cross member used to work out angles.
    [​IMG]

    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.

    [​IMG]

    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.

    [​IMG]

    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).

    [​IMG]

    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.
    [​IMG]
    [​IMG]
    [​IMG]
     
  2. VanRex

    VanRex Member

    Messages:
    258
    Location:
    Central Coast NSW
    Here is some pictures of the motor mounted on the cross member. Still have to complete the gearbox mounting.
    [​IMG]
    [​IMG]


    Got some pipework bent up for the radiator pipes. As I could not take the car to the bender I bent up some wire and took it to the exhaust shop. Got it pretty close and only had to make sone minor adjustments with the oxy. Big thanks to Erina Mufflers for this work.
    [​IMG]

    Also made a reducer from a flared peice of exhaust pipe and a truck exhaust coupler. I still have to cut out a V ans re-weld to angle it more towards the MAF sensor so the 80mm flexible hose doesn't have such a bend in a short distance.
    [​IMG]

    Changed the bottom fuel line fitting from a 1/4 to a 5/16 by cutting the old one out and silver soldering a threaded base in with the new fitting. Could change this easily for a 3/8 fitting at a latter date if I need to. also added a fuel return and another vent for the tank using the same fittings.
    [​IMG]

    Mounted the MAF and a douf douf pod filter under the spare wheel in the fresh air compartment this will be sheeted in to create a cold air box. Charcoal canister will also sit in this area.
    [​IMG]

    Regards
    Brendan
     
  3. Split 1

    Split 1 New Member

    Messages:
    7,037
    Location:
    Adelaide
    F#@k me, thats a hell of a lot of work.
    Well done that man, great to see that you have done your homework.
    Not that I would know anything about fitting a suby, but it looks great.
    I also know this van, it was used as a work van by Kruger signs, then bought by Dan.

    Keep us posted with more , I love seeing full on jobs like this.

    Dave
     
  4. KahunaKombi

    KahunaKombi Super Moderator Staff Member

    Messages:
    19,541
    Location:
    Bracken Ridge, Qld
    Hey Brendan - how's the Resto going - progressing happily we hope :lol:
     
  5. VanRex

    VanRex Member

    Messages:
    258
    Location:
    Central Coast NSW
    Bert,
    Did not do a real lot over the break. Back into it now though.

    Cut out all the ply sheeting for the floor and engine cover area. Finished the fuel tank mounting. Made new battery harness and isolator switch wiring (big heavy stuff, no voltage drop here!)

    Will post some more pics soon.

    Regards

    Brendan
     
  6. KahunaKombi

    KahunaKombi Super Moderator Staff Member

    Messages:
    19,541
    Location:
    Bracken Ridge, Qld
    Good to hear Brendan :wink:
     
  7. Damo

    Damo New Member

    Messages:
    373
    Location:
    Mount Coolum,QLD
    Can't wait to see how she goes!Thanks for the wheels Brendan,gottem yesterday 8)
     
  8. vwrx

    vwrx New Member

    Messages:
    84
    Location:
    ADELAIDE
    Are you sure thats a WRX engine ? or is it a rs liberty?
    I was sure that the rex only had air to air intercoolers or have you changed it?
     
  9. VanRex

    VanRex Member

    Messages:
    258
    Location:
    Central Coast NSW
    Yep, it's a 95 WRX. Had a air to air intercooler but I bought the liberty water to air unit and circulating pump and radiator. Going to fit a second radiator and possibly a draw through fan and water sprayer also for those real hot days when you are sitting in traffic.

    The motor has a TD05H turbo on it. The Legacy/Liberty units had TD04s.
    It only has 77,000 ks on it with real good compression and leak down results so it should work fine.

    Progress has been slow lately. Hot weather and surfing have combined to get in the road.

    Have been fabricating all the plywood flooring and storage enclosures for electricals etc.

    Brendan
     
  10. vwrx

    vwrx New Member

    Messages:
    84
    Location:
    ADELAIDE
    Noice, I have had a T25 on the road since 1999 with a Import Legacy motor in, I had 167kw From the Flywheel with some small mods. Took it down the drags with auto and 1900kg .Did a respectable 16.02 with 60km head wind.
    Was fun to drive but have sold this to a mate for my current project is complete
     
  11. KahunaKombi

    KahunaKombi Super Moderator Staff Member

    Messages:
    19,541
    Location:
    Bracken Ridge, Qld
    How's it going Brendan got any progress photo's?
     
  12. VanRex

    VanRex Member

    Messages:
    258
    Location:
    Central Coast NSW
    Bert,
    A little slow at the moment. Changeover of kids sport from Cricket to Soccer and daughter working some nights and weekends means the wife and I are constantly playing bus driver.

    I've mainly been collecting bits for the exhaust I'm about to create (mandrel bends, flanges etc).
    Also about to start a under gearbox mount using type 1 mounts with a custon bracket that picks up the lower 4 bolts of the 2 litre box. This will allow for removal of the engine without having to support the box.
    I'm also going to make a bar that mounts between the rear chassis rails to reduce the chance of chassis twist under acceleration and also hang the muffler from.

    Picked up a nice set of bucket seats for it a couple of weeks ago for $60.
    Cut out the rusted battery and smoothed the whole right side of the van (took 9 hours labor) a couple of weekends ago.
    Once I cut out the fron cab floor sections I can weld in the panels Roy supplied.

    As you can see no project management skills being displayed here (even though I have a diploma in it!). I'm currently using the tried and true scattergun approach so not a lot of results show until near the end.

    If I pulled my finger out and focused only on the conversion I could start the engine without too much work. I fear that doing this would mean that I would rush it onto the road and not finish all the other jobs.

    I will try to take some pics of bits of interest on Sunday afternoon and post them here.

    Regards
    Brendan
     
  13. Vito

    Vito New Member

    Messages:
    197
    Location:
    Adelaide
    yippee I have feen following this in Earnest, a great read and inspiration for what I do with my 75 bay window. Have you thought of kitting the accessories to fit it in?

    Keep the pictures coming

    Cheers

    Vito
     
  14. VanRex

    VanRex Member

    Messages:
    258
    Location:
    Central Coast NSW
    Vito,
    I'd rather leave the kits up to Custom Offroad Components. They've been around a long time and do a very well engineered job. (I remember buying parts off them for a Baja back in the early 80's). Their bar work is sensational.

    The time it took me to build the crossmember I could not get my labor component back. You are more than welcome to copy my plans although you would need to get it approved by your own engineer.

    I'm doing this all myself as I don't like to let any job beat me. My 1302 German Looker took 28 months (full body off, major rust repairs inc heater channels) and I repaired the rust, stripped it back, painted it, upholstered it (with a sewing machine), wired it, built the 2 litre for it. The only things that I farmed out were the crank case machining and the welding on the adjustable front struts (needed a certificate welder for engineering).

    Regards

    Brendan
     
  15. Vito

    Vito New Member

    Messages:
    197
    Location:
    Adelaide
    Great Job mate, yep it remeinded me of when I did up my 55 chevies, I did all the work myself too, it sure makes you feel good, although I left the stretching (limo) to teh proffessionals.

    Hope it all runs well for you and will look into it more.

    Cheers

    Vito
     
  16. VanRex

    VanRex Member

    Messages:
    258
    Location:
    Central Coast NSW
    How good were some of the Kombis at the Nats!

    The low light beige dual cab.
    The interior of the bright blue bay bus.
    The splittys!

    And I picked up a set of Audi A3 mags with 205 tyres for a song at the swap meet!

    Pulled the 2110 motor out of the bug and replaced it with the new 1600TP that I built for the daughter on Friday. Drove to the nats with the full on 58 horses pushing me along the F3. A BIG change from the 2110! Going to put the motor on the market as I have no use for it and I can't justify having that much invested in a motor and have it sit in the garage. Anyone who wants a strong and torquey motor for their bus let me know.

    Brendan
     
  17. Royce

    Royce Active Member

    Messages:
    1,226
    Location:
    Goulburn NSW
    Hey Brendan

    What are you asking for the 2110 - might be a simpler solution to rebuilding my 2L for the Camper. Can you let me know specs etc also.

    Thanks heaps

    Royce
     
  18. VanRex

    VanRex Member

    Messages:
    258
    Location:
    Central Coast NSW
    u2u sent.
     
  19. VanRex

    VanRex Member

    Messages:
    258
    Location:
    Central Coast NSW
    I promised so here is an update.

    A lot of time has been taken up with sheeting the floor and over engine fuel tank area. Tank is in place for the last time with hoses plumbed up. Still need to mount fuel pumps and swirl pot. Before final sheeting I will line the enclosure with 0,5 aluminium sheet for fireproofing.
    [​IMG]

    Floor is built up with two layers of ply, ply packing and dense foam for good support right across. Van will be carpeted up to the waist line.
    [​IMG]

    Started fabricating the exhaust. 2.5 inch mandrel bends and a custom made down pipe flange and collector. Just tacked together at the moment. Will pick up the Cat and muffler on Saturday to finish the fitting.
    [​IMG]
    [​IMG]

    Made a gearbox mount from some angle, flat bar, a couple of type one mounts and a couple of bolts. Turned out pretty well. This will allow me to remove the motor and the gearbox will stay in place.
    [​IMG]
    [​IMG]

    Reworked the radiator mount for more ground clearance. Now mounted in place with pipework 80% complete.
    [​IMG]

    You can see the hose routing. Will make nylon escution panels to locate the hoses/pipes through the chassis.
    [​IMG]

    Still need to make a small reducer and connect these hoses.
    [​IMG]

    Picked up a set of Audi A3 mags for the van. Just what I wanted. A bit of style without any bling. Spell S L E E P E R.
    [​IMG]

    Got to be comfortable as well. Will graft these buckets into it.
    [​IMG]

    Been a little busy as well building a 1600TP for the green 1302 for my daughter. Jak Rizo came round on Good Friday and we swapped the 2110 for the 1600. 100 hp to 50 hp what a difference!
    [​IMG]

    2110 out and ready for sale.
    [​IMG]

    Also ran heater hoses and new cable conduit to the front (old pipe was rusted badly). Will have quite a lot of rust repairs to do at the front as I found more other than the two floor panels I already knew about. Removed the windscreen and no suprise..rust. Under the bumper underneath rust all the way across. I will buy replacement panels to save time here. Want to get it completed for Valla. Still have to decide about the rear disc brakes. EA or Kit or other?

    Brendan
     
  20. KahunaKombi

    KahunaKombi Super Moderator Staff Member

    Messages:
    19,541
    Location:
    Bracken Ridge, Qld
    Well done Brendan - looking awesome :wink:
     

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