Lifted TDI Volkswagen Split Window Camper Bus Build

[zerobalance]

When I started reading this, I didn't realize you have at least 2 more project threads going right now. Damn you're ambitious!

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.

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

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

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 shit. 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.

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.

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.

 

[zerobalance]

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.

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 shit was swiss cheese and would have needed replaced.

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.

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 shit 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.

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.

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.

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?

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.

 

[Frodo]

Pretty sure I'm missing the input gear?

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!

 

[zerobalance]

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!

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.

 

[Frodo]

The gear looks correct, and Crown specializes in Jeeps so it should work.

 

[zerobalance]

Wellll....the chevy leaf springs are way too tall in SPOA form.

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.

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.

 

[posford]

Wellll....the chevy leaf springs are way too tall in SPOA form.

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.

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.

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

 

[zerobalance]

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

I considered Yjs but was concerned with the weight rating of them being too light. I probably should revisit it.

 

[posford]

I considered Yjs but was concerned with the weight rating of them being too light. I probably should revisit it.

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"

 

[bdkw1]

SU gives more room for steering fuckery.

 

[Penetrode Offroad]

 

[Sceep]

YJ's for sure. Might have to pull a leaf in the front.