So the first thing was to check out the mechanical side. All the suspension components, shocks etc are still VW and actually amazingly 100% with no wear. The engine was swapped by VW for a 2.0L in 1997. As you can see in the replacement engine service history, it put on 15000km in the first 3 years. When I just got it now, it had 18000km on it, pretty much unused in the last 15 years. The engine runs absolutely amazing and has no problem driving 120km/h. The gears were however hideous to try find. I couldn’t understand what was going on with its strange gearbox mounts and butchered gear links till I discovered it was actually originally an Automatic. So someone converted it, but didn’t have the correct manual components to do it.
So, out came the engine to sort out the conversion issues as well as replacing disintegrating foam seals and general clean-up.. Luckily I had a donor bus at home and was able to strip all the links, mounts and correct length half shafts to install the gearbox correctly. Engine back in and now changes gears as it should.
Next was the body work. It looked hideously tatty on the outside, but actually it is in very good condition. The caravan section is all original except for the lower rear section sprayed white when they decided to spray the cab white for some stupid reason. As it was so easy to fix, I quickly stripped the cab, got out the sandblasting gun and sandblasted under the windscreen that was pitted as well as a few other places with surface rust.
A few coats of epoxy primer over the sandblasted areas, then primer and onto final coat and in two weekends it turned into this beauty. It looked seriously hideous, but actually just spraying the cab has got it back into very good shape. I polished up the remainder of the caravan, I cant say its perfect, but still in good original condition which I will rather leave it in.
Before and after polishing the hubcaps.
Lastly, my stickers should be here this week. Gerhard had some made up for me and will add the last finishing touches to the van.
Here are a few pictures of the inside. Mine is the earliest version, which is a pity as it is the layout with the small bed inside and the door towards the front. The “double” bed is actually more like a ¾.
Still has original Jurgens crockery.
All the blinds and cushions are still original. The original carpets are also 100%, but I’ve left this laid down novilon over it to remain protected.
