EJ20T into a splitty

[AirWRX]

Here it is, orange when we bought it in 2005 off some unscrupulous scrotes from wales for twice the money it was worth, after loads of hassle, sleepless nights and police, dvla, and ssvc visits it was painted black and white, used everyday for four years and has lay in the driveway since 2009, its now having some surgery to put it back on the road

above is as bought but registered, we collected it from the first service station just over the bridge into Wales. The engine seized before we got to Swindon, My wife towed it on a rope from Swindon to Norwich which was one of the most stressful things we have done!

While I was saving for the remtec engine, I pulled out the gearbox and reduction boxes.

Then fitted a Boxwagen IRS kit and a 1303 gearbox, and some KYB gas shocks.

Had the van painted, but as you can see the door didnt fit at the front.

Here are some more pics of me ages ago stripping the filler out of the sides of the bus, there was tonnes of the poo!



It was put in Etch primer then left for about a year before we had a chance to do any more work to it.
Then the work began in earnest!
We bought this contraption.


Here is some of the manky metal underneath!






The right hand side.




The left hand side.





Despite being reported to the council for grinding at three o'clock on a Sunday afternoon by one of my delightful neighbours :butthead: I have been a little busy.
My purchased cargo doors were in need of the window surround repairing and the top hinge replacing.





Next on the list was to cut the bottom off the long panel to get access to the sills as these are next on the list of purchases.
This was eventful as these pics show.

Whats that lurking under there?

Best cut the side panel off and have a look, the panel was really badly fitted and the bottom was rotten. The swage line across the van on this side looked crap too!

side off

sill off too

WHAT THE F**K!


Next job was to cut out more








bought these from Autocraft



I then got sidetracked for a while then after a visit to a vw show I found some enthusiasm to do more stuff.









Then after a bit of a tough time personally and loads more complaints from the neighbours i started restoring the van in earnest(finding out how poo my van actually was!)






























All of this has covered the last two years of trying to get the van back on the road. I have a Subaru EJ20 Turbo from an old subaru that i bought and drove around for a few months before taking the engine and wiring loom out.
Now whith thanks to Kai and Rich Baker, things are progressing a little further. I will post more pics of stuff soon.[/img]

[easy-does-it]

Jesus, you've had your work cut out there fella

You got any other plans in mind other that the Ej lump?
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'76 bay going superfly TDI

[AirWRX]

Just trying to get the engine and gearbox in and working at the moment, I have managed to pry Rich Bakers RJES bellhousing from him and a few other helpful parts so at least at the moment I can start planning the exhaust, cooling system, heating system and more importantly the wiring. I'm so excited about the prospect of getting it working and on the road, i dont want to get distracted by more mods at the moment mate.

[richbaker78]

Fair play that is some project! So much work just to get to the conversion! Glad to see you are doing it properly!! Keep it up and keep us posted 😃

[jp]

Some great work there fella... it's gonna be one sweet bus when it's done. Really looking forward to seeing your progress on this one.


Keep us posted
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1971 Devon Bay with 1800 Ford Turbo Diesel Engine (wip)
1983 VW Golf GTI Campaign
1979 Mini 1275 GT
2013 Scirocco TDI GT

[Wilfred]

Deepest respect for all the hard work you put in this van, especially when considering all is done on the drive way outside!!!

When did you decide to go for a watercooler? Cause it seems to me, you passed the point where you could have built in an excellent spot for a radiator, in front between the seats...

any thoughts on that?
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[AirWRX]

Thanks guys, your comments are inspiring. Wilfred, it was decided back in 2009 when it was taken off the road that someday it would be water cooled. There hasn't been much in the way of planning, i seem to be making it up as i go along. I have spent the last couple of days making brackets to mount the turbo, making an exhaust manifold and up pipe. I went to an Impreza breakers yesterday and got a few bolts and a plug lead i was missing, I also came back with a bell mouth down pipe to start making the exhaust from, still need to work out where that will go and what silencer to use. I went to another breakers yesterday and spent hours looking at radiators and intercoolers to use, i came home with a bargain intercooler, radiator and double fan unit from a vw sharan which cost me the grand sum of £45. very chuffed with that. still didn't manage to find a squirrel fan and heater matrix to mess about with yet but, I have a few ideas in that department now. I'm going to mount the radiator and intercooler in between the chassis rails i think. I'll add more pics.