And so it starts.....my new T5 LWB Motion

[Markee]

Had to remove the head unit to plug in the speed sensor wire that I forgot and after using it for a few hours have chosen to move it down a little to bring it somewhat closer for use. Although now it covers the bottom pocket shelf but was only used for storage and a USB outlet so no loss really. Gets it out of driving view a bit more. Also loving Apple CarPlay too.

Have now taken delivery of all necessary parts for the refit so chatting with the neighbours for some driveway/garage space for the time it’s gonna take to do it all.

[Markee]

So here's the new 'upgraded' rear of my T5. Basically I started from scratch.

First up gutted the van and moved the rear double seat forward and across to get a much better position and increase the room behind it to accommodate a queen size sleeping platform.


Next up was to sound deaden all the walls, tailgate, roof and also add some thermal insulation to the lower wall cavities, including sliding door and tailgate.
I used Car Builders Stage 1 sound deadener and Sound Barrier Earthwool batts for insulation.
I had the 12mm mdf floor and rubber mat already so re-used them as they work well.



I then made the drawer/table/shelves/cabinet, this time opting for ply instead of mdf.


Added all my gear and I'm ready to go to back to work.


Overall very happy with the result.
To transform it into a holiday camper I basically just have to empty it and fit an infill panel (yet to be purchased/made) between the passenger wheel arch box and the main cabinet and our queen size self inflating mattress will fit perfectly.
Platform cabinet is 1850mm long and drawer and table are 1400mm deep each.
The goal was to have all my work gear available without having to move something to get to something else, be also able to chuck my MTB's in each weekend to go riding, then come holidays, pack all the camping gear in and head off into the unknown.

During the process I found the sliding door rail actually really loose and rattling around, so removed the exterior body panel, broke 5 out of the 9 clips in the process, tightened all the screws/bolts, then had to purchase 9 new updated clips to reinstall it. I also added some sound deadener to the back of it and the difference is amazing. The whole van just doesn't sound like a big tin can anymore and the ride inside is actually like being in a car.

I have a new UHF to fit next and I'll sound deaden the cabin roof at the same time as well as the 'sounds like a golf' front door seals that are on their way.

[Sunny43.5]

I like your comment "the 'sounds like a golf' front door seals that are on their way."That was the very first complaint I made to Our VW Dealer after buying our new T5.1 back a few years . Typical of dealers to nor have a F,ing clue when it comes to customers telling them their own advertising spiel , our front doors bounced back on the strikers worse than those first Chinese Cherry cars , in fact using that comparison would be an insult to the Chinese as these VW vans are somewhat very short on quality when you look deeper . When I picked the van up all they did was spray the seals with silicone and grease the latches what a joke . Like yours I have meticulously soundproofed all of our vans since our first one 20 years ago , being a Motor Trimmer by trade I made sure to not only line all the accessible surfaces but also stuffed the pillars and other areas with off cuts of old foam mattress . I think from memory I used around 20 + square meters of a high quality soundproofing which was glued to all the inside of the outer skin surfaces then backed up with blocks of foam between the side trims and the outer walls .Here is our van not long after purchase New T5 Project, fitted the windows myself and then attacked the inside , also fitted a Bilstein B3 Coil over kit from the UK to the van for easy loading of our daughter in her wheel chair . It handles exceptionally well as I use the van for weekend camping and towing Moto Cross bikes in the trailer so its loaded to the gills with stuff but never an issue with it being lowered .

[Snelens]

Impressive effort yet again Markee, I've been wondering why I havent seen your beast sitting "outside".

[Markee]

Impressive effort yet again Markee, I've been wondering why I havent seen your beast sitting "outside".

Cheers mate.
Yeah the bus got a holiday in the backyard for two weeks thanks to some very nice neighbours.

[Markee]

Fitted my UHF to the overhead compartment in the roof lining and mounted the aerial to a 90º adjustable angle bracket to the roof rack.
While the head lining was out I sound deadened the cabin roof then added Sound Batts insulation right the way through the van under the roof lining. So much quieter in there now.
Also installed the 'sounds like a golf' door rubbers, and yes, it sounds like a golf when you shut the doors now. All thud, no twang!
Got the rear Haldex coupling to service as well. Have the fluid and am ordering a new filter kit to get it done as per this link with VAGCOM VCDS.

Next up is waiting for lock down to end and off to get some under body protection sorted. Boo's Bash Plates here in VIC will make what I need as there's no off the shelf option that I've found here in Aus.

After that it is new front struts and one top mount as the bearing is shot after an altercation with a gutter at speed a few months back. While I'm there I'll be doing the front lower control arm bushes to, as they're flogged out and loose as a goose.

Also considering getting some custom spacers made to get some more lift, maybe in the range of another 30mm.

[Markee]

Update 23/10/20

Recent jobs completed as per above post was the UHF install with photos below.

Still unsure about the aerial fold down bracket and fitment location so it may change.


Next up was install upgraded Raised KVRR-18HD King Springs in the rear to compensate for added weight of the sound deadening and refit of the cabinetry.
I basically regained what I lost in height by adding the extra weight with the HD springs fitted, which is nice and will go well with the new 265/65R17 tyres I am getting fitted next week.

Here is a photo of the 3 different types of rear springs. The black one is standard VW fitment, the middle one is Raised King Springs KVRR-18 and on the left is the King Springs Raised KVRR-18HD (300-500kg constant payload).
As you can see they are all exactly the same physical height the only difference is the diameter of the spring steel therefore you can run them with a standard length shock.
Dimensions for them as follows:
Standard: 20.8mm
Kings KVRR-18: 22.4mm
Kings KVRR-18HD: 23.4mm

Actual lift is in the 35-40mm range on the rear with out any weight in the van. Loaded it is 15-20mm as my van now weighs it at nearly 2900kgs. The van now takes off with little to no squat in the rear and obviously rides higher too.


Next on the list is a set of Black Duck front seat covers. I've wanted these for years and left it way to late to save the drivers seat but alas they are on now and I think they look great.
I opted for their newer 4Elements version in Black over the older canvas style due to them being waterproof, removable and machine washable should the need arise.


Another job ticked off the list was changing out the front lower control arm bushes for a set of SuperPro Poly bushes with offset castor adjust for the rear set to get a better wheel alignment done as the van has always pulled left on the highway.
Even without a wheel alignment the van drives much better in a straight line and the steering response is much, much quicker.


While doing the control arm bushes I also replaced the left front strut top bearing as I hit a gutter at reasonable pace unexpectedly and it pretty much destroyed the bearing.

I have also got a Bowden's Own Bumper Repair kit to bring the old faded grey sun damaged ones back to life. Just waiting for a day where the weather is good for 24 hrs as you can't get them wet for 12hrs once it's done
Visually, with the new bigger tyres, I think it's going to dramatically change the look of the van, which I can't wait.

[wintrmute]

I used the Bowden's Own Mr Black on my bumpers, and the results were really good. Although it hasn't been long enough to tell how long it lasts.

[Markee]

I used the Bowden's Own Mr Black on my bumpers, and the results were really good. Although it hasn't been long enough to tell how long it lasts.

I saw it on the Transporter/Caddy FB group so thought I'd give it a try. Good to hear first hand experience. Cheers

[Mtwem]

Keen to see how the bumpers turn out and the new tyre look

[wintrmute]

Hope you don't mind me hijacking your thread - but this was the result of Mr Black on my rear bumper.

[Markee]

Hope you don't mind me hijacking your thread - but this was the result of Mr Black on my rear bumper.

This is great mate, exact picture I saw on Facebook.

[wintrmute]

haha oh no, worlds colliding!

[Markee]

Keen to see how the bumpers turn out and the new tyre look

Here you go mate. One sneaky one for now and will grab some new photos after the next camping trip this coming weekend.

Also got some 25mm spring spacers coming to get just that little bit more lift, you know cos bigger is always better haha.

[Mtwem]

Nice looks good! how was the application onto the bumper ? pretty straight forward? did you need to tape up anything?
Cheers