Harold - the T25 van (1.8T content)

[GeorgeMK1]

I spent the past month playing around and adding some additions to Harold again.
I was on the fence for a while what to do with the stance, whether to lower it by 80mm all round and run some BBS RS with widened lips. If this option was taken, the van would be a strict beach cruiser and camper only, as getting off road would be hard. The other option was to have a lift kit and big muddies on widened steelies. Full roof rack set with over head fog lights etc. Issue with the second option is the engine was too weak to run any larger sized wheels at all.

Here is a quick test fit of my 17x8 BBS RS I had laying around. After this i decided against it, as much as I wanted to have a proper stance on him, I knew that practicality would be thrown out of the window.




I also did two minor upgrades that made a huge difference. I installed a proper set of Morel splits at the front and tweaters mounted on the dash. (I dont have many pics for this part unfortunately). Second install was a cup holder. We got the idea from the net of some folks in the U.S that used Honda CRV folding cup holders. We went to the local wrecker and found the cleanest one. Its so funny as it fits like a glove. Fits perfectly around the handbrake assembly and all, we were stoked! 2 bolts and it was on solid.








Then i started designing the next over head shelf before I set off to Mt Hotham for snowboarding. I made the shelf to fit small, light weight things - in this example it was my gloves, beanies, thermals, tops etc. I set out making the frame and then re-enforcing it with 6mm marine plywood. Then I finished with a door, handle and a spot for an extra speaker too!
Its on pretty sturdy and holds plenty of useful things. Really happy with this particular addition.











My gf then gave the idea to do a nice feature wall with 'Harold' on it. So she drew it up, and then I finished off the staining. Turned out awesome and we love it!! All coming together nicely

[GeorgeMK1]

So this is the post where things went badly.

About 2 weeks ago I took off for a weekend in Mt Hotham to snowboard and test the van out in full blown winter mode. I took off straight after work and everything was going perfect. Stopped in Bright for a bite to eat and decided to keep going all the way to the top in the same night. After Harrietville the hills start to become like a rally course ... I was loving it. Music full pumping and me smashing through the gears going uphill.





I hadn't noticed but the water temp gauge was slowly increasing. By the time I noticed it, I had no where to stop as the road to Hotham is very tight and winding. Just before I stopped I heard a big POP and I knew that a rad hose has blown. I was now in the middle of Harrietville and Hotham with 0 reception at 12pm. So I started the motor for 20 seconds, did a u turn and then coasted the entire 15km downhill with the engine off and my butthole clenched super tight. Made it safely and from there organised the most expensive tow in my life. Regardless still have a super fun weekend boarding and my gf came all the way from Melbourne on Sunday to pick me up haha, what a champ.

At the time I was reaaaaaally pee'd off but after a day or two I was actually super excited as now I get to swap in my 1.8t from a MK4 GTi that I had initially intended to use in my MK1 GTi. I will be using a Kennedy Engineered adaptor plate (already ordered) to match the gearbox and engine. 228mm custom flywheel with VR6 clutch and plate. I've already pulled the motor out and am now replacing anything and everything I can get my hands on. Have also ordered a new radiator as I have a feeling that was a big culprit in the over heating issue. Adaptor should be here next Monday-ish and then I'll start making the custom mounts from there

No engine hoist needed in my driveway, no thank you

[Sunny43.5]

How much adaptation did it require to do the swap of engines mounts electrics etc . I did a major one back in the early 80's to a Toyota Hi Ace van I owned , it had a poor little 1.6 engine or less from memory . So with no former training or qualifications I reefed out the 4 pot job and shoe horned a Holden 186 6 pot job along with its powerglide auto the two speed one . Handmade my own engine mounts and new crossmember for the auto , Fitted the Holden diff [wheels stuck out from the side by a fair bit but at least it looked mean ] shortened the tailshaft again no balancing worked fine . Lastly had to add an extra radiator to increase capacity , the original was up under the body vertical infront of the engine but did not get enough cooling for the big six . Mounted a Holden one from an EH but placed it horizontally under the front and connected it to the heater hoses . Went like stink on the road great fun at the lights . Love the work you have done so far keep up the updates on the project .

[Bryn23]

Loving the Thread, good to see a old van get some love.

looking forwards to the review once you put in the new engine.

Good to see the insulation working, i used the 4mm Thermalbane Amatelin closed cell on my floor on top of resort found deadening and it will be used on the internal Panels as well when i get around to carpeting them (i have Resomat sound deadener and 10mm closed foam everywhere on internal walls and roof)

[GeorgeMK1]

How much adaptation did it require to do the swap of engines mounts electrics etc . I did a major one back in the early 80's to a Toyota Hi Ace van I owned , it had a poor little 1.6 engine or less from memory . So with no former training or qualifications I reefed out the 4 pot job and shoe horned a Holden 186 6 pot job along with its powerglide auto the two speed one . Handmade my own engine mounts and new crossmember for the auto , Fitted the Holden diff [wheels stuck out from the side by a fair bit but at least it looked mean ] shortened the tailshaft again no balancing worked fine . Lastly had to add an extra radiator to increase capacity , the original was up under the body vertical infront of the engine but did not get enough cooling for the big six . Mounted a Holden one from an EH but placed it horizontally under the front and connected it to the heater hoses . Went like stink on the road great fun at the lights . Love the work you have done so far keep up the updates on the project .

Hey Sunny, I haven't gotten to that stage just yet. Engine mounts will have to be custom made, I am hoping to re0use the original moustache bar and modify some longitudinal audi engine mounts to fit. Electrics should be pretty easy, this motor is the earlier 1.8T with fewer sensors and DBW so relatively easy. This particular engine came out of my old mk1 cabby, so I have already ore wired it all.
I'm sure the your van would have been epic, I'm surprised the gearbox held up with all the extra power haha?

Loving the Thread, good to see a old van get some love.

looking forwards to the review once you put in the new engine.

Good to see the insulation working, i used the 4mm Thermalbane Amatelin closed cell on my floor on top of resort found deadening and it will be used on the internal Panels as well when i get around to carpeting them (i have Resomat sound deadener and 10mm closed foam everywhere on internal walls and roof)

Hey Bryn, yeah mate so far the amatelin has been pretty decent. How do you like the resomat? Any good for vapour and condensation?
Theres quite a bit of brain work involved in insulating a van, I don't think I'e done it the correct way at all, but time will tell haha.

I'll be sure to update it for sure with the new engine

[Sunny43.5]

Hey Sunny
I'm sure the your van would have been epic, I'm surprised the gearbox held up with all the extra power haha?

I fitted the Powerglide auto that was already built for those 6 pot motors it came with the whole engine from a wreckers .

[Bryn23]

The Resomat's main quality is that it reduces the sound, which it really has helped, i would guess the aluminium reflective layer helps retain a little heat and the insulation with the 10mm Closed foam with reflective layer helps with the heat lost.

The only real thing that fixes condensation in cold climates is little air flow, which means some form of heating with a hatch or window ajar to reduce condensation build up.

Im looking at getting a diesel heater for next winter, as you can have all the insulation in the world, but if there is no heating, then its still going to be cold, although less cold and wet than without insulation.

For the time being, camping with enough bourbon reduces feeling the cold

[GeorgeMK1]

I fitted the Powerglide auto that was already built for those 6 pot motors it came with the whole engine from a wreckers .

Oh sorry mate, I guess I'm not very familiar with the Holden brand.

The Resomat's main quality is that it reduces the sound, which it really has helped, i would guess the aluminium reflective layer helps retain a little heat and the insulation with the 10mm Closed foam with reflective layer helps with the heat lost.

The only real thing that fixes condensation in cold climates is little air flow, which means some form of heating with a hatch or window ajar to reduce condensation build up.

Im looking at getting a diesel heater for next winter, as you can have all the insulation in the world, but if there is no heating, then its still going to be cold, although less cold and wet than without insulation.

For the time being, camping with enough bourbon reduces feeling the cold

Hahahaha, that would fix a lot of issues that's for sure.

How exactly does the diesel heater work? I'm assuming its just a generator of sorts? I've seen quite a few heaters under the seat where it hooks up to the engines coolant system and it gets its heat from there... which sounds like a normal car heater anyway haha.

I found that when I was in Hotham (well almost), that being under the blankets wasn't cold at all for me. Only early morning having to get up and dressed was freeeezing haha. I actually got a little butane heater, but the issue is it needs an open window otherwise it uses up all the oxygen in the van - which essentially defeats the purpose I guess

[Sunny43.5]

I get my sunroofs from a huge worldwide company called Webasto they manufactuer and sell heaters for RV's and cars as well , whilst that department is separate from our sunroof side they sell all their products via a dealer network or maybe you can get one direct from their Australian office in Kirrawee .NSW .Here is their heater page , small note they are a bit dearer than some others so do your homework .Webasto: Retrofit Parking Heaters From memory when i was last at the RV and Caravan show , the unit runs off the cars own fuel and its external with the heater element part blowing heated fresh air into the cab no fuel fumes etc .Short video here not certain if this the right style for you .Webasto parking heater - functioning - YouTube

[Bryn23]

Yeah Sunny is on the ball, Webasto are the big brand of air heaters,

Im looking at the Webasto: Recreational vehicles heating solutions: Air Top

It is slightly different to the parking heater sunny lined, the air top is used a lot in Europe, its a simple heater that taps into your diesel tank, or seperate tank, its designed for long term running

Ill be using a seperate tank for the 2000 STC as i don't have easy access to my tank, and with a 120ml-240ml diesel draw per hour i can get away with a small under floor mounted tank.

There are a heap of cheap copies available on eBay that would do the job as well, as long you can buy the servicing parts.

[Abyss]

Looking good fella, I had a T25 in the UK with a mk2 golf gti engine, 8v, shifted very well indeed! On the look out for another panel van here in Melbourne.
I would advise against that roofing insulation though, as it does collect and hold moisture against the panels, I know its behind a vapour barrier. If you want to use it, bag it first. I insulated my van too much, (50mm and 25mm celotex) its so much now that it holds the heat in the summer!
May see you if you get to one of the next vanlife meets (I couldn't make the one you went)

Few pic's of 'gay steve'

[Abyss]

Regarding heating, I run an eberspacher d2 heater, 12v for the fan and glow plug, uses minimal power really, and if its on all night a coke cans worth of diesel. I plumbed it into the fuel tank sender on its own pickup (few cms off the bottom of the tank). Once you have a heater setup like this, you wont look back. I went without for years, but now i couldnt imagine winter camping without it! Keeps the mrs happy too! Chris Jeffs has just installed one in his LT, ordered a new one from the UK, same week delivery, cheaper than anywhere else.

[GeorgeMK1]

Thanks Sunny and Bryn, will have to look into that when some cash rolls in as the van has drained my pockets. Hopefully will look into it before next winter as if it only drains as little as you say, that's a small price to pay for a comfy warm van!!


Hey Abyss, gay steve looks surprisingly straight! I've always loved panel vans, I secretly wished I found a panel van instead haha. I'm glad to hear the 8v went hard, I can only hope the 20vt will be even better.
Mate there is a vanlife meeting happening next month which you should def check out! Unfortunately I wont have Harold on the road just as yet.

As for the insulation on the roof. I have stuck it firmly to the roof, but I do understand condensation and moisture can f*** everything up. During summer we have all windows down anyway, so hopefully that solves the moisture issue. Time will tell.

[GeorgeMK1]

After dropping the engine on the weekend, I had some time on Monday to work on Harold. Figured I would split the gearbox and engine right there and then to make it easier to move them around. Engine has been put aside for now until I can figure out what to do with it. Gearbox has gone into my little assembly area.







Then Tuesday after work I cleaned the engine bay and removed things that arn't needed.







Then we get to last night were I was pretty productive. To my surprise all the parts I ordered came in yesterday at the same time.
So we got - radiator, adaptor kit incl. flywheel, drive flange seals, and alloy fuel line.

I borrowed the VW seal remover from work and removed and replaced the seals with new ones.




While I was working on the gearbox I went by the instructions of the adaptor plate kit and cut off 7/16" off the input shaft to allow the custom flywheel to do its thing. So I used a clamp for accurate measure.






This is what the adaptor plate and custom flywheel looks like. After some testing it turns out I can't use my 228mm VR6 clutch and pressure plate as I'd hoped as the flywheel is made to work with the standard 228mm bus clutch. So I've ordered a new 228mm SACHS clutch and throw out bearing. Also did a quick test fit of the adaptor plate and everything lines up well.




On Tuesday I unexpectedly sourced a K03s turbo (in the background) from a forum member Peter, just to add in a bit more torque to the motor when driving. So will be cleaning that and throwing it on along with all new gaskets and such. Currently at my desk at work and looking on ETKA for new washers and o rings for all the turbo feed/return lines

In the picture you can also see the engine mount I was planning to use. Came off of a Audi B4. The passenger side fits fine, but the issue is on the drivers side. The turbos on the AGU and B4 Audi are both different, meaning I cant use the drivers side engine mount. So I'll have to custom make that side of the engine mount once the motor is in the van.



You can see the issue here. The turbo would go straight onto the engine mount bracket.



And that's how I ended the night last night. This is my little work space to assemble everything, at least it keeps the rain away
Cheers!

[jets]

I borrowed the VW seal remover from work and removed and replaced the seals with new ones.

Just wondering, do you work on VWs for your day job?