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Old 16th August 2013, 23:05   #61
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Originally Posted by narendra.vw View Post
Details: Engine:---- 50cc kick starter TVS make.
Wheels & tyres:---Scooty
Brakes:---Drums, (Back two wheels, cable operated.)
Power:---Back right wheel. chain driven.
Highlight :- It had tie rod end for steering rod to absorb shocks( little bit)
Fuel tank::--Kerosene stove tank.
Fuel used:--petrol.
Seat:--Normal Domestic plastic seat legs removed.
Total Cost on those days:-- App 15,000/--
You are awesome narendra. The can is coming out beautifully too. Hope the friend paid you when he took the cart. (Y)
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Old 17th August 2013, 19:03   #62
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Default Re: My TD to TDI VW Van (1990 model)

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Originally Posted by getsurya View Post



unveiling ceremony soon
Thanks. YES. Once the new wheels are fitted I will .Still to take good shots of the van on a bright sunny day.
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Old 17th August 2013, 20:13   #63
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Default Re: My TD to TDI VW Van (1990 model)

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Originally Posted by kash_pegasus View Post
You are awesome narendra. The can is coming out beautifully too. Hope the friend paid you when he took the cart. (Y)
Thanks . I presume van . Yes he paid. some formalities.

Last edited by narendra.vw : 17th August 2013 at 20:16.
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Old 18th August 2013, 18:32   #64
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Thanks . I presume van . Yes he paid. some formalities.
I am sorry I meant the van. I mostly use t-bhp mobile app and end up with such spelling mistakes at times due to my phone's gesture typing mode!
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Old 18th August 2013, 18:40   #65
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Default Re: My TD to TDI VW Van (1990 model)

Small details of engine bay

1) Valve door breather with oil separator ( Bad air is let out, not routed back to intake. Only oil collected, goes back to crank case.) It is behind the hose.

2) Coolant pump OE. Speeds up coolant circulation from radiator (located in front of the van along with ac condenser) to engine when AC is switched on.

Radiator cooling fan has two speeds . Engine uses only low speed even with ac on . Non audible inside.(Bangalore weather).Directly connected to check high speed, it works, but audible .
May be it comes on when it sees a good looking split.

3) Acc alternator for second battery. Main alternator is below it.

4) Hot water feed to front hot air blowing system.

5) The Red part visible is clutch cylinder.

6) The main hose running from engine to radiator.

Rest of working parts, you all will be knowing. Most of it.

PLEASE NOTE, I have not left one hose rubbing each other. Narrow hoses has cushioning to each other. Rest are well strapped.
Yes I know, odd looking fuel line pipes will be replaced.

Yes, Yes,, I just got a call from my K&N supplier that my order has arrived. Now, tyre has to wait little longer.

My TD to TDI VW Van (1990 model)-engine-mounted.jpg

Some idea of oil separator
My TD to TDI VW Van (1990 model)-cimg1740.jpg
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Old 19th August 2013, 15:30   #66
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Default Re: My TD to TDI VW Van (1990 model)

Excellent work mate. That wooden flooring and sliding drawers are awesome. Awaiting for the unveiling ceremony.

And, I think I got the answer for your earlier disappointment that you are not getting much response or questions.
It may be because, your ultra detailed work is like Greek & Latin to me (may be for most of the people too ). Till date, at least I haven't seen this type of a restoration. Only very few can do it. Kudos to your passion and patience mate.

So in my case, except observing what you are doing and wondering about how you are doing it, I couldn't do much.
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Old 19th August 2013, 15:37   #67
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Default Re: My TD to TDI VW Van (1990 model)

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Originally Posted by kash_pegasus View Post
I am sorry I meant the van. I mostly use t-bhp mobile app and end up with such spelling mistakes at times due to my phone's gesture typing mode!
That's OK Kash, "Bada Bada dasho ma hisa chote chote bathi hothi raheti hi". In English this phase does not sound good, so I preferred OE.(HINDI)
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Old 19th August 2013, 19:40   #68
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Default Re: My TD to TDI VW Van (1990 model)

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Originally Posted by madhav14 View Post
Excellent work mate.

And, I think I got the answer for your earlier disappointment
your ultra detailed work is like Greek & Latin to me. your
you are doing it, I couldn't do much.
Thanks madhav, You read my mind & felt my heart. Put your mind ‘Yes I can’ you too can do magic & of Corse M factor. Now a days we prefer off self. Easy way out. This looses creativity.

The new K & N Air filter, costing 10K+ is making my budget slightly imbalanced . Tyre has to wait a bit longer & waiting for bright sunny day too. I want first impression to be good.
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Old 19th August 2013, 20:58   #69
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Default Re: My TD to TDI VW Van (1990 model)

Glimpse of what suppose to come. Rally 2000 is with me right from my gypsy days (yr 1990 ) It has 100 watts bulb. (flash bulb used in still camera.)

Please note, no clamps or wire is visible under it. Other set came along with the van as OE. Hella make.
My TD to TDI VW Van (1990 model)-diff-angle.jpg
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Old 20th August 2013, 21:27   #70
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Default Re: My TD to TDI VW Van (1990 model)

Very comprehensive set of mods done on an old VW van. I'm still surprised how you managed to fit the engine that way.

The blue coloured mount speaks of your own ingenuity in accommodating AC compressor.The look outside and inside is as close to OE as possible. The Innova seats don't appear out of place in the Caravelle. It looks as if an ardent fan modernised his beloved classic van with love. The floor, the catcher switch, the small luggage compartment and other useful bits in the interior speak volumes of the exquisite amount of detail you took care of while doing this project.

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Old 21st August 2013, 17:12   #71
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Default Re: My TD to TDI VW Van (1990 model)

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Originally Posted by JustCause View Post
I'm still surprised how you managed to fit the engine that way.

The blue coloured mount speaks of your own ingenuity in accommodating AC compressor.The look outside and inside is as close to OE as possible.

Thanks, JustCause, Small detail of right engine mount
MS plate:--50 mm wide, 8 mm thick
Holes :- The three holes you see goes in same place (Engine} as OE.
single hole for bedding mount
the rod :-Solid rod 1" thick got bend with Iron smith.
welding part was done in co 2 welding more flexible & stronger.
now ac pipes can go through it. Thanks again for your absorbvation.
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Old 21st August 2013, 21:28   #72
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Default Re: My TD to TDI VW Van (1990 model)

Hello Narendra. Such a gem of a restoration project you've undertaken! Kudos to what is turning out gradually. Will definitely be a head-turner!
And this explanation of every intricate detail shows your love and emotional quotient that you have towards this beauty.
Wishing you, all happy miles ahead!
And please do not bother about the response issues. Keep up with the great work and the fruits are definitely going to be real sweet!
P.S.: Will be following this thread each day for your updates.
Regards.
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Old 22nd August 2013, 18:38   #73
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Default Re: My TD to TDI VW Van (1990 model)

Thanks Twistof Fate & I love to see you become bhpian soon .

Yet again, SUN is playing hide & seek in Bangalore. I will wait for weekend.

Yes, I got the new air filter. Very cute to look at.
Got new tyre fixed to the disc. Yet to fit it to the van & get the alignment done. I think I made the right choice (tyre Size.) Not to big or to small.

Since we have to wait until weekend, I want to bore you with some more of my back log.

Due to sunroof, OE ac duct was not possible. It used to run parallel to the van’s length.
I made some modification to the same duct to run perpendicular to the van’ length.
Air throw is fair enough for front seats. Plenty for middle & back row seats.

My TD to TDI VW Van (1990 model)-ac-duct-fix.jpg
My TD to TDI VW Van (1990 model)-duct-close-up.jpg
My TD to TDI VW Van (1990 model)-ac-duct-roof-fix.jpg

Few more new parts arrived.
My TD to TDI VW Van (1990 model)-more-acc.jpg

Clear lens for indicator It also has distance bulb in it.
My TD to TDI VW Van (1990 model)-more-indcator-fixed.jpg

Plastic cover for door lever removed & metal cover replaced
My TD to TDI VW Van (1990 model)-more-door-lever-metal.jpg

My favorite horn, Bosch. Chrome grill horn. Been with me past 20 yrs.
( Remember starting of funky town song same sound tune. )
My TD to TDI VW Van (1990 model)-bosh-horn.jpg

German innovative thinking & metallurgy .

Cross ventilation, You don’t have to breath your own air.
My TD to TDI VW Van (1990 model)-cross-vent.jpg

My TD to TDI VW Van (1990 model)-catcher.jpg
My TD to TDI VW Van (1990 model)-catcher-1.jpg


Custom made tool for lifting or aligning the engine. It may work for your requirement.
My TD to TDI VW Van (1990 model)-jack-engine-costum-made.jpg


Just for the knowledge Idea for your personal garage .
Name:  SerpentbyBashkoTrybekModularFurniture.jpg
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Size:  32.0 KB

I am eagerly waiting for a sunny day.
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Old 25th August 2013, 17:36   #74
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Default Re: My TD to TDI VW Van (1990 model)

I am in the process of fixing the new air filter Old routing need’s slight modification.

In the mean time, Finished work details.

Hatched. Seeing it‘s first day light.
Name:  disc seeing its firstl ight..jpg
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Never mind once new tyre covers it.
Name:  disc details.jpg
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OE type centre hub cap fitting.
My TD to TDI VW Van (1990 model)-check-nut-cap.jpg

Since check nut (Rear wheel.) projects out, OE hub cap position is not possible.
Made an extension sleeve of length 20 mm in aluminum.
My TD to TDI VW Van (1990 model)-extension-sleeve.jpg

Tight press fit Photo shows sleeve & cap fixed.
My TD to TDI VW Van (1990 model)-check-nut-cap-later.jpg

Front sub axle arm was just missing inner disc edge by 2 mm.
Made 4mm spacer to make the gap increase.
My TD to TDI VW Van (1990 model)-spacers.jpg

Arrow showing sub axle where disc has narrow gap.
My TD to TDI VW Van (1990 model)-suspension-front.jpg

Front wheels have a dust cap. Still scratching my brain to find a way to fit the hub cap
Please note:-Front wheels have bolts & rear wheels have studs. Nuts were very expensive Rs200/- per piece
(F & B carry 14 mm lug.)
My TD to TDI VW Van (1990 model)-wheel-disc-hardware.jpg

I had not choice in design with my spec.
16” disc with 6.5J you get many design in 112 pcd. Benz, Audi .
My TD to TDI VW Van (1990 model)-new-wheel.jpg

Comparing gypsy tyre to the van’s new tyre. Gypsy is on right side Spec:--R15”, 75/ 195.
My TD to TDI VW Van (1990 model)-compare.jpg

Just for the knowledge. Helps in cars which have Rear hatch opening eg: van
If hatch Struts are weak or to keep Hatch open for longer time with something hanged to it this will be helpful. ( car stationery only) This can done by anyone who has little knowledge about cutting tools.
Things needed, tool:-axe frame with blade, Bottom channel which holds the door glass eg : mm540.very cheap available any spare shop.
Measure the length of the fully stretched door Strut rod. Cut the channel to the measured length.
Press fit it to the rod, now you can breath easy. Don’t forget to remove it before closing the door. Car tool bag is the best place it to go back.

My TD to TDI VW Van (1990 model)-stay-channel.jpg

Attached.
My TD to TDI VW Van (1990 model)-stay-shocks.jpg
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Old 30th August 2013, 19:35   #75
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Default Re: My TD to TDI VW Van (1990 model)

Front roof ac duct got wasted once it was cutoff from rear air supply. (Culprit, sun roof.)
I tried to make use of those duct space . Series of development photo follows.

OE Roof ac duct of the van.
Name:  gsobild_1593.jpg
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Made duct mouth wider & made doors for it. Knob to open the door. Note:-- Tinker’s quality work can be seen..
Front roof duct with door.(looks like it wants to communicate with me.)
My TD to TDI VW Van (1990 model)-sun-shade.jpg

Since front seats were missing facing air throw, I thought of putting small cute blower into it.
Blower with two ducts. ( to be fixed in the rectangle gap)
My TD to TDI VW Van (1990 model)-mini-blower.jpg

Fitted back to the van. Centre Empty space will be used for 9” monitor.
My TD to TDI VW Van (1990 model)-cimg1812.jpg
My TD to TDI VW Van (1990 model)-cimg1816.jpg

Air filter box opened. (bottom right corner is k & n air filter wrap.)
My TD to TDI VW Van (1990 model)-air-filter-box-opened.jpg

Air filter matching data of different vehicles.
My TD to TDI VW Van (1990 model)-data.jpg

Comparing the new & the old air filter.
My TD to TDI VW Van (1990 model)-air-filter-cumpre.jpg

Filter fitted to the engine bay. Please note:-Filter wrap on it.
My TD to TDI VW Van (1990 model)-filter-fixed-wrap.jpg

Before starting I scanned with my pocket scan. Got two faulty codes
My TD to TDI VW Van (1990 model)-scanned.jpg

Code one :-- P0101. p/d (Means, kept in pending mode). MAS. New air filter should rectify it.
Code two:-- P0401. EGR gas insufficient. I had blocked the pipe from exhaust to EGR valve. Reason, I dint want inlet to get dirty & clogged .Now I have to remove the blockage. This has something to do with emission. This system lower the combustion temp & helps in low emission.
My TD to TDI VW Van (1990 model)-codes.jpg

Just for the knowledge.
Rear mounted cross section of engine & gearbox layout.
Name:  engine details.jpg
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This week’s time was taken away by new air filter fitting & rectifying faulty codes . Once trial run is satisfied( No check light) Van will be going for new wheel's balancing & alignment .
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