Lifted TDI Volkswagen Split Window Camper Bus Build

Frodo said:
When I started reading this, I didn't realize you have at least 2 more project threads going right now. Damn you're ambitious!
Click to expand...
Actually I'm just an idiot. I'm fortunate to be in a position that I don't have to do a ton of actual work anymore to pay the bills, and when I do take on paying work, I charge a decent amount. I just took on this VW thing that another shop gave up on after tearing it apart and doing a bunch of shoddy metalwork. It will carry me for a while.
20240922_155125.jpg


Onto the old bus again. Sorry on the photos, I think I clicked a tab on my phone and messed up the aspect ratio on this batch.
I finished up the main rails and outriggers
20240923_141955(1).jpg

Then I set up the laser again, this time with the horizontal plane in mind. Way the hell off.
20240923_143154.jpg


I spent probably 4 hours on getting it straight. Sucks but absolutely necessary, I would be driven nuts if the body was not perfectly square to the chassis and it would look like ****. Ended up using a combination of screw jacks, floor jack, I beams, ratchet straps and anything else around, including an adjustable rear track bar off a mustang as a turnbuckle.
20240923_163009.jpg



I ended up with it being within .0625" all around, which is probably more square than it has been in 50 years, even got the cargo door opening square and the doors to actually close correctly, which they never really have.
20240923_163000.jpg


Cut some .125 wall 1.5" square tube I had around to start attaching the body to the frame, got two of them in before I ran out of time. Hopefully tomorrow morning I can get the rest of it attached and cut out the front seat pedestals.

20240923_171714.jpg
 
I figured the best way to tie the body back in was to add a 1.5" square tube on top of each rock slider, which got me a lot closer to the stock body profile, then I triple checked everything was reasonably straight, and started welding the body back to the sliders.
20240924_120553.jpg
20240924_120550.jpg


Everything is less wet noodle like now, so I chopped out the front pedestals. This more reinforced my decision to go this way, all this **** was swiss cheese and would have needed replaced.
20240924_135941.jpg


And out came what was left of the front frame rail and steering box, etc. This box feels tighter than the one in the bus I'm driving, so I might swap them out.
20240925_163513.jpg


Then I built a sorta jig out of I beams and stuff to get the front rails hanging level and square out in space. I hit it to within .2 degrees according to my digital level. I suppose I could have plugged all this into fusion and tried to do strength calcs, but it's heavier than any CJ frame out there, and once it has crossmembers, I suspect will be bomb proof. I do plan to fish plate the joints, just for piece of mind. I'm far from a professional welder, so I expect to see this **** in the ghetto fab thread, some of those downhill welds got jacked because my angle was garbage, and also because I'm a hack and a fraud.
20240925_163520.jpg


Stubbed out the front. I'm not quite sure how I'm going to finish this out yet. I do plan to put a winch behind the nose, but that depends on where I can sneak in a radiator. The giant holes were needed to get the factory front rails out completely.
20240925_163507.jpg


Also, the dana 20 I bought on ebay finally showed up a month later. I can't complain too much, It was cheap enough and seems in good condition.
20240926_061031.jpg

I need to call Novak I guess and figure out the adapter situation to mate this thing up to the NV3550. I'm planning to build my own cable twin sticks (unless something cheap turns up used) because who doesn't want a VW bus that can do front digs?
20240926_061034.jpg

Pretty sure I'm missing the input gear? I know little about this cases, and need to look at a diagram. I probably should open it up and do new bearings and stuff anyhow.

That's where I'm at now. Waiting on some spring bushings and need to get U bolts made to hang the front axle, and need to hurry up and make a decision on rear spring packs.
 
zerobalance said:
Pretty sure I'm missing the input gear?
Click to expand...
You are. In stock form, its bolted onto the output of the transmission and the transfer case just slides over it.
I've only played with CJ5 dana 20s, that shifter is kind of cool!
 
Frodo said:
You are. In stock form, its bolted onto the output of the transmission and the transfer case just slides over it.
I've only played with CJ5 dana 20s, that shifter is kind of cool!
Click to expand...
That makes more sense. This is supposedly from an older FSJ? I agree the shifter setup is neat, they gave me the actual shifter itself too,

Based off what novak has listed here, they sell a kit for 10 spline input, and summit has the gear (I think it's correct) here.
 
The gear looks correct, and Crown specializes in Jeeps so it should work.
 
Wellll....the chevy leaf springs are way too tall in SPOA form.
Screenshot_20240929_163123_Gallery.jpg
Screenshot_20240929_163150_Gallery.jpg


So two options. Return the spring to summit, which is free, and I'm only out like $11 in shipping, and try maybe waggy springs? or go SPUA.
20240929_162946.jpg
20240929_162944.jpg


Spring under makes things look much nicer, and I imagine it would improve handling with there being less leverage on the spring. I'm also worried this springs are way too freaking stiff, being meant for a chevy truck and all, I don't know if pulling leafs will help. I'm damn close to going back to trying to run a 3 link.
20240929_163003.jpg
 
zerobalance said:
Wellll....the chevy leaf springs are way too tall in SPOA form.
Screenshot_20240929_163123_Gallery.jpg
Screenshot_20240929_163150_Gallery.jpg


So two options. Return the spring to summit, which is free, and I'm only out like $11 in shipping, and try maybe waggy springs? or go SPUA.
20240929_162946.jpg
20240929_162944.jpg


Spring under makes things look much nicer, and I imagine it would improve handling with there being less leverage on the spring. I'm also worried this springs are way too freaking stiff, being meant for a chevy truck and all, I don't know if pulling leafs will help. I'm damn close to going back to trying to run a 3 link.
20240929_163003.jpg
Click to expand...
I had a buddy in HS who SAS'd a 95 Ranger with squarebody front leafs. Might as well have welded the axle in solid. I gotta imagine the front of the VW weighs less than that Ranger did.

I'd be looking for some YJ springs, maybe pull a leaf or 2
 
posford said:
I had a buddy in HS who SAS'd a 95 Ranger with squarebody front leafs. Might as well have welded the axle in solid. I gotta imagine the front of the VW weighs less than that Ranger did.

I'd be looking for some YJ springs, maybe pull a leaf or 2
Click to expand...
I considered Yjs but was concerned with the weight rating of them being too light. I probably should revisit it.
 
zerobalance said:
I considered Yjs but was concerned with the weight rating of them being too light. I probably should revisit it.
Click to expand...
I think even if you wind up adding leaves to the pack its a closer starting point.

Quick look, YJ and wagoneers use same length spring, YJ is centered pin, waggy is offset ~1"
 
Penetrode Offroad said:
Bruh. This should have been at KOH, woulda made it further than the Phar Passat wagon.
Click to expand...
I've been following his stuff for a while. The approach is ....interesting, but I won't bag on him because my **** doesn't run.

Kinda put this on hold for a bit. My car lot and parts business got super busy and I figured I should stack some money as we are looking at buying a 80 acre property adjacent to our farm, on top of that, I got tired of mud so had to scrape up extra cash to pay to concrete my driveways and around the shop, so that slowed down free time and ate a **** load of money. I'm going to knock out my 5.0 quick, and get back to this and my 79 ford soon.

I also might have the opportunity to buy this thing, so that has me rethinking some aspects. An already engineered forward control chassis is appealing.

man g9.jpg


It's a Volkswagen / Man G90. Basically a big VW bus called the LT 40 on top of a MAN truck chassis. Not sure If I will get it, but hedging my bets until it plays out.
 
zerobalance said:
I've been following his stuff for a while. The approach is ....interesting, but I won't bag on him because my **** doesn't run.

Kinda put this on hold for a bit. My car lot and parts business got super busy and I figured I should stack some money as we are looking at buying a 80 acre property adjacent to our farm, on top of that, I got tired of mud so had to scrape up extra cash to pay to concrete my driveways and around the shop, so that slowed down free time and ate a **** load of money. I'm going to knock out my 5.0 quick, and get back to this and my 79 ford soon.

I also might have the opportunity to buy this thing, so that has me rethinking some aspects. An already engineered forward control chassis is appealing.

man g9.jpg


It's a Volkswagen / Man G90. Basically a big VW bus called the LT 40 on top of a MAN truck chassis. Not sure If I will get it, but hedging my bets until it plays out.
Click to expand...
So what kind of suspension and driveline does that have? I’ve seen Man trucks, but they were all big semi kind of stuff. They had weird suspension too. I know they make their own diesels, but again big stuff.
 
zerobalance said:
I've been following his stuff for a while. The approach is ....interesting, but I won't bag on him because my **** doesn't run.

Kinda put this on hold for a bit. My car lot and parts business got super busy and I figured I should stack some money as we are looking at buying a 80 acre property adjacent to our farm, on top of that, I got tired of mud so had to scrape up extra cash to pay to concrete my driveways and around the shop, so that slowed down free time and ate a **** load of money. I'm going to knock out my 5.0 quick, and get back to this and my 79 ford soon.

I also might have the opportunity to buy this thing, so that has me rethinking some aspects. An already engineered forward control chassis is appealing.

man g9.jpg


It's a Volkswagen / Man G90. Basically a big VW bus called the LT 40 on top of a MAN truck chassis. Not sure If I will get it, but hedging my bets until it plays out.
Click to expand...

Oh ****, it's the same one: 1988 Volkswagen-MAN G90 FAE 4x4 5-Speed | PCARMARKET

1744449285103.webp
 
Yeah, it was a cool truck before it burned. It's probably not feasible a a base for my old bus, but I might try to buy it and build a LT van sometime down the road with it.

I kinda had a moment of weakness and sold off the TDI engine for 2k ( paid $350 for the whole car), the jeep transmission, and the adapter. Keeping the toyota axles still but looking at an alternate driveline that packages better and is overall better suited for a camper setup.

That's all I'm saying for now, trying to learn from all the past missteps I've made on this thing and have a concise plan going forward.
 
WaterH said:
That thing is cool, except no AC.

Looks like the winch can go out the front or back.

IMG_2422.png


IMG_2423.png


It has no def and no computers. My kind of truck.
Click to expand...

AC can be retrofitted to anything if you're dedicated. Easiest with a van. But trying to find enough stuff to rebuild a cookout like that will be a challenge.
 
I'm quite certain that I have turned this into every thread I ever made fun of for going completely sideways, and I don't blame anyone who busts my balls considering how many times I've changed my direction in the past few years. I'll be the first to admit that I have the worst ADHD of anyone and get distracted/fail to plan. So thanks for attending my Ted talk....

With all that said. I sold off all the TDI and Jeep parts......packaging all of it under the floor was nightmare, when it came to shift linkages, plumbing, intercooler, radiator, suspension members, etc. I make it a point to think about all the projects I have going on for a bit every day, then make notes as I get inspired with how stuff on them can work. Probobly not the best method, but it is creative at least. I kinda was stuck until I ran across this fella:
EV Land Cruiser

In the past, I owned a F150 powerboost, and loved the utility of it. The rest of the truck sucked, but it was nice having a 7.2kw plug in the bed, and leaving the AC on when you were eating lunch was a good feature. It was amazing to travel and camp with. Having the tent air conditioned when I was 100 degrees in South Dakota was handy. The battery was tiny, like 1.5kwh, so it rarely was EV only.
20220730_182810.jpg


So, while an EV will not work for my current situation, a hybrid certainly will. I've started playing with ChatGPT and it's a wildly inaccurate, but a fun tool to bounce my dumb ideas off of to refine them into something that can be actually researched. Through a lengthy ChatGPT thread, about a million google searches, and reading posts all over about conversions, I think I have landed on a viable setup, that checks all the boxes, and packages easy.

  • Nissan Leaf donor car. Ideally 2016-2017, they have a 30KWH battery vs 24KWH in older cars, and the batteries are supposed to be a bit better. They are easy to control with open source controls. I've been watching and think I can get a decent donor for under 3k
  • The leaf motor spins at like 10k rpm max and is most efficient at 6500ish. So major gear reduction is needed. I weighed the options of doublers, and what I have, plus passenger side drop. This might all fail, but my plan is to use a couple of t cases I have like $150 total invested into. Pull the planetary case off a 241j from a JK (2.72:1) and mate it to a Toyota VF1A from a V6 runner. Will have to make the adapter and a shaft, but I have resources to do that. with 4.10 gears, it puts the sweet spot at 58mph.
  • The hybrid part comes from a free Kubota D1305 from an IR air compressor. Nice and compact, sips fuel, and zero electronics to make run. Mated to a generator head that will make 6kw continuous. Tuck it in the back under the OG engine lid.
  • A 30KWh battery in this thing, should net 75-100 miles on ev only. The genset will charge from 80% in 4-5 hours. If we camp on grid, we can plug in, and I plan to add a charge port to take advantage of EV charge stations.
  • I'm estimating total weight at around 4500 pounds all in, which sounds heavy until your realize a tiny nissan leaf is 3600. A stock syncro Vanagon could easily tip the scales at 4500 with like 75HP.
Still rolling all this around, but I am actively looking for a Leaf donor, and plan to cut up the transfer cases before too long to see how to mate them. I already own the Kubota diesel, and have ebay search alerts for a lot of the other parts.
 
zerobalance said:
I'm quite certain that I have turned this into every thread I ever made fun of for going completely sideways, and I don't blame anyone who busts my balls considering how many times I've changed my direction in the past few years. I'll be the first to admit that I have the worst ADHD of anyone and get distracted/fail to plan. So thanks for attending my Ted talk....

With all that said. I sold off all the TDI and Jeep parts......packaging all of it under the floor was nightmare, when it came to shift linkages, plumbing, intercooler, radiator, suspension members, etc. I make it a point to think about all the projects I have going on for a bit every day, then make notes as I get inspired with how stuff on them can work. Probobly not the best method, but it is creative at least. I kinda was stuck until I ran across this fella:
EV Land Cruiser

In the past, I owned a F150 powerboost, and loved the utility of it. The rest of the truck sucked, but it was nice having a 7.2kw plug in the bed, and leaving the AC on when you were eating lunch was a good feature. It was amazing to travel and camp with. Having the tent air conditioned when I was 100 degrees in South Dakota was handy. The battery was tiny, like 1.5kwh, so it rarely was EV only.
20220730_182810.jpg


So, while an EV will not work for my current situation, a hybrid certainly will. I've started playing with ChatGPT and it's a wildly inaccurate, but a fun tool to bounce my dumb ideas off of to refine them into something that can be actually researched. Through a lengthy ChatGPT thread, about a million google searches, and reading posts all over about conversions, I think I have landed on a viable setup, that checks all the boxes, and packages easy.

  • Nissan Leaf donor car. Ideally 2016-2017, they have a 30KWH battery vs 24KWH in older cars, and the batteries are supposed to be a bit better. They are easy to control with open source controls. I've been watching and think I can get a decent donor for under 3k
  • The leaf motor spins at like 10k rpm max and is most efficient at 6500ish. So major gear reduction is needed. I weighed the options of doublers, and what I have, plus passenger side drop. This might all fail, but my plan is to use a couple of t cases I have like $150 total invested into. Pull the planetary case off a 241j from a JK (2.72:1) and mate it to a Toyota VF1A from a V6 runner. Will have to make the adapter and a shaft, but I have resources to do that. with 4.10 gears, it puts the sweet spot at 58mph.
  • The hybrid part comes from a free Kubota D1305 from an IR air compressor. Nice and compact, sips fuel, and zero electronics to make run. Mated to a generator head that will make 6kw continuous. Tuck it in the back under the OG engine lid.
  • A 30KWh battery in this thing, should net 75-100 miles on ev only. The genset will charge from 80% in 4-5 hours. If we camp on grid, we can plug in, and I plan to add a charge port to take advantage of EV charge stations.
  • I'm estimating total weight at around 4500 pounds all in, which sounds heavy until your realize a tiny nissan leaf is 3600. A stock syncro Vanagon could easily tip the scales at 4500 with like 75HP.
Still rolling all this around, but I am actively looking for a Leaf donor, and plan to cut up the transfer cases before too long to see how to mate them. I already own the Kubota diesel, and have ebay search alerts for a lot of the other parts.
Click to expand...

What vehicle is this going in? You need 20kw continuous to be able to do highway speed in most cars. Electric cars looked like frisbees for decades because they had to get drag super-low to make them work.
 
That's a good question and why I post this stuff, because I have no clue what I'm talking about. About 16kwh at 60mph is my estimate, if it's just flat out running 60, with no stopping, then like 85 or so miles. 6kw won't keep up, but if it's boosted, it will do 125 or so. Might be wise to go to a 10k or larger genset I guess. There also is the option of a modular battery pack added for longer trips. All food for thought and I certainly don't pretend to be an expert on this ****. The only time I was involved in EV's was one of my enginnering professor's having a s10 with like 30 lead acid batteries, circa 2003.
 
zerobalance said:
That's a good question and why I post this stuff, because I have no clue what I'm talking about. About 16kwh at 60mph is my estimate, if it's just flat out running 60, with no stopping, then like 85 or so miles. 6kw won't keep up, but if it's boosted, it will do 125 or so. Might be wise to go to a 10k or larger genset I guess. There also is the option of a modular battery pack added for longer trips. All food for thought and I certainly don't pretend to be an expert on this ****. The only time I was involved in EV's was one of my enginnering professor's having a s10 with like 30 lead acid batteries, circa 2003.
Click to expand...
Thanks to Dougal I see my plan has a big flaw, but it can be overcome and might actually make more sense.

Remove the kubota and replace with a common rail 2.0 VW tdi. Bit more complex but I already have an ecu to run it standalone. That engine will two of these to make 30kw of power and get close to being able to drive indefinitely.

So revised plan is to stuff two 30kwh leaf packs in the bus, make it 100% ev most of the time with maybe 200 miles range. Build the tdi into a modular powerpack/range extender and build a trailer to take it and haul gear on long trips. Then we can take the RTT for my kids to sleep in, and take kayaks, bikes, whatever. Dump the trailer at basecamp and use the bus to explore.

Still a lot of noodling to do, but it is feasible.
 
zerobalance said:
Thanks to Dougal I see my plan has a big flaw, but it can be overcome and might actually make more sense.

Remove the kubota and replace with a common rail 2.0 VW tdi. Bit more complex but I already have an ecu to run it standalone. That engine will two of these to make 30kw of power and get close to being able to drive indefinitely.

So revised plan is to stuff two 30kwh leaf packs in the bus, make it 100% ev most of the time with maybe 200 miles range. Build the tdi into a modular powerpack/range extender and build a trailer to take it and haul gear on long trips. Then we can take the RTT for my kids to sleep in, and take kayaks, bikes, whatever. Dump the trailer at basecamp and use the bus to explore.

Still a lot of noodling to do, but it is feasible.
Click to expand...

Yeah that little kubota is indirect injection, which means it'll use about 20% more fuel than a VW TDi doing the same job.

You know that nothing beats a manual gearbox for efficiency right? It's going to be cheaper and much, much, easier to do a manual driveline and carry a separate gen-set than anything else.
 
You must log in or register to reply here.
Top Back Refresh