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Old 01-30-2013, 02:05 PM   #1
Xtremjeepn OP
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Talking Screwing around with a VW Eurovan!

Well, I have always loved the VW vans, especially the Vanagon Westfalias. Unfortunately, they are getting old, expensive for a nice one and can't fit a motorcycle in the back

With my first kiddo on the way I figured I should start nesting by building a family camper

I really wanted something that I could park in my driveway in an HOA controlled neighborhood that doesn't allow "Commercial" vehicles or Campers. Which kinda eliminated just doing a slide-in in my pickup or a Sprinter Van. Both would have been cool, but this is going to be fun for now too!

Over in the UK they build these T4 vans into campers all the time.

First off I found a deal on a 2002 GLS, hardtop 7 passenger van, diagnosed with needing a timing chain tensioner. Original owner van. Well cared for but he did not want to spend the $5k they quoted to do the timing job I offered him $1,350 and he took it


So here is the project van !





I also stumbled on a wrecked 1993 "Weekender" Poptop. Picked this one up for $1250




Now ll I had to do was make the first one run and convert it to a pop top




I couldn't store the parts van more than a few days without causing issues with the HOA so I posted it up for parts on TheSamba and Ev_Update. I put the extra parts out there for "any reasonable offer"! I literally took anything people offered and did zero negotiation just to get the parts gone and off to a good home!

Within 3-4 days I had the van stripped and $1400 back in my pocket

Took the empty shell off to the recycler.




Now for the rear fun!
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FOR SALE 02 F650GS DAKAR
FOR SALE 2 KLR650s http://coffeemotorcycleswine.blogspot.com/
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Old 01-30-2013, 02:13 PM   #2
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Talking

The next step was to tear down the 2002 and figure out the issue.



.....and clean up some parts while I was in there





Take apart two 7 passenger vehicles and you will have plenty of seating for the next garage party




Gotta love a design where the timing chains are on the back side of the motor so the transmission has to come out to change them.






Long story short, the chains, tensioners and guides were fine So this part of the job ended up being preventative maintenance since these vans will eventually need chains.



The real issue turned out to be this tiny steel screen jamming the cam adjuster. (Only had to take it apart twice to figure this out)




Engine was Sea Foamed and all of the crud inside it is now gone too!
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06 KTM 950 Adventure(The Fainting Goat)
FOR SALE 02 F650GS DAKAR
FOR SALE 2 KLR650s http://coffeemotorcycleswine.blogspot.com/
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Old 10-31-2014, 11:47 AM   #3
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Quote:
Originally Posted by Xtremjeepn View Post
The next step was to tear down the 2002 and figure out the issue.




would it kill you to put up some dry wall?
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Old 10-31-2014, 12:02 PM   #4
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Originally Posted by focallength View Post
would it kill you to put up some dry wall?



There are things I'm good at and things I'm not.

I really want to finish my garage but keep getting sucked into other projects that are easier for me to do.

Anyone want to come help finish the garage?
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Cole Ford<----my iPad app ...and iPhone version.....Android Tablet version

06 KTM 950 Adventure(The Fainting Goat)
FOR SALE 02 F650GS DAKAR
FOR SALE 2 KLR650s http://coffeemotorcycleswine.blogspot.com/
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Old 10-31-2014, 01:00 PM   #5
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There were a few trim pieces that were never quite right on this build. The rear panel where the child seat teathers stick through was one of them. The donor being a 1993 did not have the hooks and the 2002 did. So there were no holes for them.

When I originally cut the holes there were some mistakes and they looked like crap! I've been trying to find the proper panel with no luck. So instead I redid the panel with carpet to make it look much better!

Untitled by Mōtum Magazine, on Flickr
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Cole Ford<----my iPad app ...and iPhone version.....Android Tablet version

06 KTM 950 Adventure(The Fainting Goat)
FOR SALE 02 F650GS DAKAR
FOR SALE 2 KLR650s http://coffeemotorcycleswine.blogspot.com/
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Old 10-31-2014, 07:11 PM   #6
Xtremjeepn OP
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Untitled by Mōtum Magazine, on Flickr
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06 KTM 950 Adventure(The Fainting Goat)
FOR SALE 02 F650GS DAKAR
FOR SALE 2 KLR650s http://coffeemotorcycleswine.blogspot.com/
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Old 10-31-2014, 07:46 PM   #7
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Quote:
Originally Posted by Xtremjeepn View Post
There are things I'm good at and things I'm not.

I really want to finish my garage but keep getting sucked into other projects that are easier for me to do.

Anyone want to come help finish the garage?
I will totally come over and finish you garage.....if you build me out a eurovan

JP
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Old 10-31-2014, 07:50 PM   #8
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Wicked

Quote:
Originally Posted by Jholmes105 View Post
I will totally come over and finish you garage.....if you build me out a eurovan

JP
GarageMahall here we come!
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Cole Ford<----my iPad app ...and iPhone version.....Android Tablet version

06 KTM 950 Adventure(The Fainting Goat)
FOR SALE 02 F650GS DAKAR
FOR SALE 2 KLR650s http://coffeemotorcycleswine.blogspot.com/
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Old 11-01-2014, 07:23 AM   #9
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Quote:
Originally Posted by Xtremjeepn View Post
Anyone want to come help finish the garage?
Not this time of year; I've developed an allergy to snow.

I prefer OSB sheeting (for durability), painter's caulk the seams, commercial exterior primer, and semi-gloss commercial exterior paint (semi-gloss cleans easier). It'll look fantastic.

My garage done that way (still working on the shop):

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Old 01-30-2013, 02:18 PM   #10
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First test drive went well





A buddy of mine came over to help me put the transmission back in the Eurovan and fell in love with my wife's F650 Dakar He had (and hasn't ) ever ridden before. But fell so in love with the idea of riding something like the Dakar that he went out and bought one Of course, I was happy to put the van project on hold and go help him pick it up. (Notice the lack of headliner as I was just about to cut the top open)

Josh is now a member here and waiting to go take his MFS course in a few weeks



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Cole Ford<----my iPad app ...and iPhone version.....Android Tablet version

06 KTM 950 Adventure(The Fainting Goat)
FOR SALE 02 F650GS DAKAR
FOR SALE 2 KLR650s http://coffeemotorcycleswine.blogspot.com/
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Old 01-30-2013, 02:27 PM   #11
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Laugh

Slight problem after picking up his motorcycle. I apparently didn't get one of the axle shafts torqued enough and dropped it on the way home in 10* weather. Abandoned the van in favor of margaritas for the night and came back and fixed it in the day light

This is where the real fun is! Nothing quite as fun a cutting a giant hole in the top of a van you just bought




Now through the power of the Internet I'm going to skip lots of boring details and TA DA!






One of the big things I was able to do with this build so far was retain the rear AC unit that GLS vans came with and factory pop tops did not!



This right now is a giant AC blower. I will duct it up to the trim pieces later



I currently have this set up like a stock Weekender with the 4 person sleeping and a table. I will now start converting it to a true camper.
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Cole Ford<----my iPad app ...and iPhone version.....Android Tablet version

06 KTM 950 Adventure(The Fainting Goat)
FOR SALE 02 F650GS DAKAR
FOR SALE 2 KLR650s http://coffeemotorcycleswine.blogspot.com/

Xtremjeepn screwed with this post 01-30-2013 at 05:28 PM
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Old 01-30-2013, 03:05 PM   #12
seuadr
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that thing is choked full of badassery.

also, i totally understand about the 650 dakar. it looks like serious business.
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Old 01-30-2013, 03:59 PM   #13
a1fa
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my hero!
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Old 01-30-2013, 05:17 PM   #14
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Okay, I have to share this.


While I was searching for my Eurovan I would save all sorts of cool photos of Eurovans and Vanagons I found along the way. Mostly just to remember ideas of builds, mods etc.

I stumbled on a cool cartoon sketch of one and saved it. This is it!



After I found the black 2002 van online it started a long email conversation with the owner while we were negotiated the price and discussed the condition of the van.

In our exchange of emails he sent me this sketch below through email.



I replied and said...."Hey, that's pretty cool" and shared the one I had found earlier. His reply was "yeah, I drew that one too" :shock:

Really? Sweet!

So we have continued to talk and I have been emailing him updates on the van. At one point I kinds mentioned doing a "Transsyberia " theme like the Porsche Cayenne Transsyberia race cars.

He then emailed me this.





This showed up in my mailbox!!!!

Think I may need to finish the framing and find a place to mount it in the van when its done!



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Cole Ford<----my iPad app ...and iPhone version.....Android Tablet version

06 KTM 950 Adventure(The Fainting Goat)
FOR SALE 02 F650GS DAKAR
FOR SALE 2 KLR650s http://coffeemotorcycleswine.blogspot.com/
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Old 01-30-2013, 05:20 PM   #15
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Current interior set up is fairly close to a stock Westfalia Weekender. The rear seat folds to a bed, there is a food out table in the wall, bed in the Poptop. I'm not going to install the rear facing jump seats in favor of some seat swivels on the front seats.



The goal is to build something like this!

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06 KTM 950 Adventure(The Fainting Goat)
FOR SALE 02 F650GS DAKAR
FOR SALE 2 KLR650s http://coffeemotorcycleswine.blogspot.com/
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