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Mk5 tourneo jag-van mk2

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Re: Mk5 tourneo jag-van mk2

Postby robbie.cee » Wed Aug 30, 2017 8:30 am

Sure a big hammer could fox that!
Last van i bent door skin but it pulled the lip inwarda at bottom... really wants a tiny bit of metal chopping out of rear part of inner door

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Re: Mk5 tourneo jag-van mk2

Postby Pocketrocket » Wed Aug 30, 2017 11:07 pm

bambi mk 1 wrote:
Pocketrocket wrote:
robbie.cee wrote:Rolling wont do more than pull arches outwards more so more likely to rub aint it? On the door i mean


Na im not flaring them just rolling the lip on the inside, its that thats catching the tyre wall, i recon once thats rolled it'll be sound :wink:

A twinwheel jumbo roller and rail will cure it :wink: Cant remember it might be just the rail you need :)
https://www.donedeal.ie/commercials-for ... t/15548658 On second thoughts the bulge might be too far to the rear :(


Yeh the rail would probably benefit from being spaced out 2-3mm as it just catches the wall of the tyre but i can live with it, the tyre only fouls on the inside lip of the arch so it's that whats getting rolled inwards, the arch will stay exactly the same from the outside as i want it looking standard-ish :lol: if it wasn't for the mk3 axle the rears would be miles outside the arch!
1999 mk5 tourneo (previously jagvan, now Vw PD powered)
2000 mk5 with a jaguar twist :wink: (now dead but will live on)
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Re: Mk5 tourneo jag-van mk2

Postby Pocketrocket » Wed Aug 30, 2017 11:15 pm

robbie.cee wrote:Sure a big hammer could fox that!
Last van i bent door skin but it pulled the lip inwarda at bottom... really wants a tiny bit of metal chopping out of rear part of inner door


Sounds a bit extreme! :shock:
Ive got the 2 spare vans still parked up waiting for me to chop them for the trailer project so have a couple of rollers/guides that I can pinch/look at modding to see if I can get the door spaced more outward that way, first thoughts is that I'll have to extend the runner slightly after the bend inside the van to accommodate a bigger/extended runner/guide if you get me?
1999 mk5 tourneo (previously jagvan, now Vw PD powered)
2000 mk5 with a jaguar twist :wink: (now dead but will live on)
1996 disco 300tdi 1.2 offroad toy :D
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Re: Mk5 tourneo jag-van mk2

Postby CamperVanBeethoven » Thu Aug 31, 2017 8:49 am

Just been looking over this thread. Van looks and sounds way cool and very rapid.

I want one now, do you fancy doing another one? :D
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Re: Mk5 tourneo jag-van mk2

Postby bambi mk 1 » Thu Aug 31, 2017 11:35 am

Pocketrocket wrote:
robbie.cee wrote:Sure a big hammer could fox that!
Last van i bent door skin but it pulled the lip inwarda at bottom... really wants a tiny bit of metal chopping out of rear part of inner door


Sounds a bit extreme! :shock:
Ive got the 2 spare vans still parked up waiting for me to chop them for the trailer project so have a couple of rollers/guides that I can pinch/look at modding to see if I can get the door spaced more outward that way, first thoughts is that I'll have to extend the runner slightly after the bend inside the van to accommodate a bigger/extended runner/guide if you get me?

Pity it hasn't two side doors :( You could convert to gullwings and it would fly :lol: Wouldn't doubt it after all the work you have done already 8)
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Re: Mk5 tourneo jag-van mk2

Postby ned » Thu Aug 31, 2017 11:45 am

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Re: Mk5 tourneo jag-van mk2

Postby mike En » Fri Sep 01, 2017 7:12 am

Pocketrocket wrote:
robbie.cee wrote:Sure a big hammer could fox that!
Last van i bent door skin but it pulled the lip inwarda at bottom... really wants a tiny bit of metal chopping out of rear part of inner door


Sounds a bit extreme! :shock:
Ive got the 2 spare vans still parked up waiting for me to chop them for the trailer project so have a couple of rollers/guides that I can pinch/look at modding to see if I can get the door spaced more outward that way, first thoughts is that I'll have to extend the runner slightly after the bend inside the van to accommodate a bigger/extended runner/guide if you get me?


I had that idea for mine, extend it out and space the rest out, the only problem I found was that the runner itself would then catch the door when it was opened, as it is my door card just touches the runner !

I also thought about using the kinked runner from the big twin axle vans with the side door and extended arches (forgot what there called lol) but then realised the kink was in the wrong place, think the best bet is to space the end out 5-10mm and reduce the spacers along it so it sits at an angle.
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Re: Mk5 tourneo jag-van mk2

Postby Pocketrocket » Fri Sep 01, 2017 1:41 pm

CamperVanBeethoven wrote:Just been looking over this thread. Van looks and sounds way cool and very rapid.

I want one now, do you fancy doing another one? :D


Thanks for the nice coments,..........but no I don't want to do another :lol: :lol:
There has been times when ive thought "what the hell am I doing here! Shouldv'e just stuck with the di" :| but now she's running-ish I'm glad I persevered and can see the potential at the end.

The trailer is the next project once this is ironed out a bit more :wink:
1999 mk5 tourneo (previously jagvan, now Vw PD powered)
2000 mk5 with a jaguar twist :wink: (now dead but will live on)
1996 disco 300tdi 1.2 offroad toy :D
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Re: Mk5 tourneo jag-van mk2

Postby Pocketrocket » Fri Sep 01, 2017 1:47 pm

mike En wrote:
Pocketrocket wrote:
<span class="skimlinks-unlinked">robbie.cee</span> wrote:Sure a big hammer could fix that!
Last van i bent door skin but it pulled the lip inwarda at bottom... really wants a tiny bit of metal chopping out of rear part of inner door


Sounds a bit extreme! :shock:
Ive got the 2 spare vans still parked up waiting for me to chop them for the trailer project so have a couple of rollers/guides that I can pinch/look at modding to see if I can get the door spaced more outward that way, first thoughts is that I'll have to extend the runner slightly after the bend inside the van to accommodate a bigger/extended runner/guide if you get me?


I had that idea for mine, extend it out and space the rest out, the only problem I found was that the runner itself would then catch the door when it was opened, as it is my door card just touches the runner !

I also thought about using the kinked runner from the big twin axle vans with the side door and extended arches (forgot what there called lol) but then realised the kink was in the wrong place, think the best bet is to space the end out 5-10mm and reduce the spacers along it so it sits at an angle.
bambi mk 1 wrote:
Pocketrocket wrote:
robbie.cee wrote:Sure a big hammer could fox that!
Last van i bent door skin but it pulled the lip inwarda at bottom... really wants a tiny bit of metal chopping out of rear part of inner door


Sounds a bit extreme! :shock:
Ive got the 2 spare vans still parked up waiting for me to chop them for the trailer project so have a couple of rollers/guides that I can pinch/look at modding to see if I can get the door spaced more outward that way, first thoughts is that I'll have to extend the runner slightly after the bend inside the van to accommodate a bigger/extended runner/guide if you get me?

Pity it hasn't two side doors :( You could convert to gullwings and it would fly :lol: Wouldn't doubt it after all the work you have done already 8)


Daft as it sounds me and luke have thrown ideas around like that for the trailer project
But I think for the trailer it wouldn't be the best use of space altough it would look cool as f@@k!! 8) 8)
It'll be a mania this year so you'll all have to pop by and have a look and throw me some ideas :wink:
1999 mk5 tourneo (previously jagvan, now Vw PD powered)
2000 mk5 with a jaguar twist :wink: (now dead but will live on)
1996 disco 300tdi 1.2 offroad toy :D
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Re: Mk5 tourneo jag-van mk2

Postby robbie.cee » Sun Sep 17, 2017 12:29 am

My van its the tire itself that fouls a bit on inner skin in lower rear corner of door where the skin curves away from outer profile by about 30m near the skeletonised area... on my old van i banged it which fixed that but buckled lower lip in a bit and looked crap.. so a strategic lil chop or scollop with a tiny cutoff disc would totally solve issue. Could prob reverse cut bit and weld back inwards??

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Re: Mk5 tourneo jag-van mk2

Postby Pocketrocket » Mon Sep 18, 2017 10:41 pm

robbie.cee wrote:My van its the tire itself that fouls a bit on inner skin in lower rear corner of door where the skin curves away from outer profile by about 30m near the skeletonised area... on my old van i banged it which fixed that but buckled lower lip in a bit and looked crap.. so a strategic lil chop or scollop with a tiny cutoff disc would totally solve issue. Could prob reverse cut bit and weld back inwards??


Managed to roll the arch lip in on Saturday morning with lukes arch roller, its not done the entire lip but its done more than enough for the tyre not to foul anymore, sorry robbie I didn't get any pics as I had a small list of snagging jobs to sort before mania :lol:
1999 mk5 tourneo (previously jagvan, now Vw PD powered)
2000 mk5 with a jaguar twist :wink: (now dead but will live on)
1996 disco 300tdi 1.2 offroad toy :D
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Re: Mk5 tourneo jag-van mk2

Postby Pocketrocket » Mon Sep 18, 2017 11:08 pm

So not much to report lately, as above I've got the arches rolled so now don't catch, fitted my amp and sub in the boot area for a better quality sound and got the bonnet painted in the same colour (although it will need doing again as the paint underneath has still reacted with the lacquer despite having 5 layers of high build primer to seal it :( )

Ive fitted a 12" fan to the rad (instead of the 8") so should now be more than man enough to keep her cool 8)

Also had a main water hose burst while driving up sheffield parkway next to the water pump, was a t##t to get to but thankfully no serious damage done :shock:

Ive also started to make the pannel thats missing from the bottom/front of the middle row seats, im incorporating some usb, 12v power sockets and a pop out cup holder for the young uns. Just needs carpeting when it's finished.

Lots of little teething/snagging problems but we're getting there :wink:
Sorry no pics just a couple I took on my way home Saturday
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1999 mk5 tourneo (previously jagvan, now Vw PD powered)
2000 mk5 with a jaguar twist :wink: (now dead but will live on)
1996 disco 300tdi 1.2 offroad toy :D
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Re: Mk5 tourneo jag-van mk2

Postby Pocketrocket » Wed Sep 20, 2017 6:25 pm

Another small update with jobs ive gotten done before mania this weekend.

The towbar is now wired back in after I had that and the bumper off for welding, I've fitted a fuel cooler from a bmw x5 on the return line (I'll explain why in a second) and loosely fitted the seat panel ive made for the rear seats, needs wiring up before the final fit.

The reason for the fuel cooler is due to it having a plastic tank, (im assuming) the returned fuel when warm/hot makes the tank expand and this makes my fuel guage read wrong and also the pick up pipe will be further away from the fuel in the bottom and potentialy running making me run out of fuel till it shrinks back down :lol:
The next thing to look at if this doesn't cure the problem is a blocked vent on the tank its self :?:
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1999 mk5 tourneo (previously jagvan, now Vw PD powered)
2000 mk5 with a jaguar twist :wink: (now dead but will live on)
1996 disco 300tdi 1.2 offroad toy :D
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Re: Mk5 tourneo jag-van mk2

Postby Pocketrocket » Tue Oct 17, 2017 10:21 pm

Right chaps its time for a little update as it been a few weeks :wink:

Not realy that much to report, got mania of the way and since then ive just been using the van for normal day to day stuff and is a god send compared to the discovery for getting the mrs' wheelchair in/out.

A few parts have been ordered and 1 of which has landed in the shape of a new 76mm throtle body :D
Compared to the standard 52mm mondeo/cougar 1 ive been using (the origional jag was fly by wire) It's mahooosive!!

While ive been mocking that up on the spare engine/inlet ive reworked the idle control valve position so will hopefully give be better idling when the revs are suddenly dropped as occasionally it will stall. Im just waiting for some silicone hoses to arrive before I can fit them.

Anyway as usual a few pics 8)
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1999 mk5 tourneo (previously jagvan, now Vw PD powered)
2000 mk5 with a jaguar twist :wink: (now dead but will live on)
1996 disco 300tdi 1.2 offroad toy :D
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Re: Mk5 tourneo jag-van mk2

Postby BROWNYS V6 » Tue Oct 17, 2017 10:29 pm

Pocketrocket wrote:So not much to report lately, as above I've got the arches rolled so now don't catch, fitted my amp and sub in the boot area for a better quality sound and got the bonnet painted in the same colour (although it will need doing again as the paint underneath has still reacted with the lacquer despite having 5 layers of high build primer to seal it :( )

Ive fitted a 12" fan to the rad (instead of the 8") so should now be more than man enough to keep her cool 8)

Also had a main water hose burst while driving up sheffield parkway next to the water pump, was a t##t to get to but thankfully no serious damage done :shock:

Ive also started to make the pannel thats missing from the bottom/front of the middle row seats, im incorporating some usb, 12v power sockets and a pop out cup holder for the young uns. Just needs carpeting when it's finished.

Lots of little teething/snagging problems but we're getting there :wink:
Sorry no pics just a couple I took on my way home Saturday


needs a slap with the lowering stick, looks a bit high in those pics, maybe its how u took them, but then slammed vans are no good as dailys, ask me how I know :roll:
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